Beam Director Optics for Focused 3D Printer Beam Shaping
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Solution Overview
Problem
Existing beam directors for 2D and 3D printers face challenges in focusing and controlling beam size on the work surface, particularly with non-collimated or asymmetrical beam sources, requiring complex optical components and calibration procedures.
Innovation Solution
A beam director system comprising a rotatable first reflector and a second annular reflector, where the first reflector rotates and reflects the beam at a constant angle, and the second reflector, which can be stationary or rotating, adjusts the beam to achieve focused, proportional dimensions on the work surface by utilizing conic and toroidal surfaces to correct beam size and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex optical components are used to focus and control beam size on the work surface, then beam focusing precision is improved, but device complexity increases
Solution Approach 1:
The patent employs curved reflective surfaces (toroidal and conic sections) instead of flat mirrors to achieve beam focusing. The first reflector uses a toroidal surface and the second reflector uses conic section surfaces, which inherently provide the necessary focusing capability without requiring additional complex optical components like lenses or multiple mirrors.
Solution Approach 2:
The patent changes the geometric parameters of the reflective surfaces (curvature radii, focal distances, angular orientations) to control beam focusing and size. By adjusting parameters such as the toroidal reflector's radius of curvature and the conic reflector's eccentricity, the system achieves precise beam control without adding complex components.
2Adaptability or versatility
If multiple optical components are used to accommodate various beam sources, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent designs the reflective surfaces with specific geometric properties (toroidal and conic sections) that can handle various beam source types (collimated, divergent, convergent, asymmetrical) through a single optical path. The same reflector configuration serves multiple beam source requirements, making the system universal without needing separate optical components for each beam type.
Solution Approach 2:
The patent uses asymmetrical conic section surfaces (ellipses, parabolas, hyperbolas) for the second reflector, which can accommodate asymmetrical beam sources and produce symmetrical focused spots, or handle symmetrical beams appropriately. This asymmetrical geometry provides versatility in handling different beam source configurations without requiring additional symmetrical optical components.
3Device complexity
If traditional beam director design is used, then structural simplicity is maintained, but beam size control capability deteriorates
Solution Approach 1:
The patent introduces curved reflective surfaces (toroidal for the first reflector, conic sections for the second reflector) that inherently provide beam focusing and size control capabilities. These curved surfaces replace the need for complex multi-component optical systems while achieving superior beam size control compared to traditional flat-mirror beam directors.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system minimizes optical components, reduces calibration needs, and effectively focuses and controls beam size in both x and y dimensions, accommodating various beam sources, including collimated and non-collimated light, and symmetrical or asymmetrical shapes, ensuring precise beam delivery to the work surface.
Implementation Method 1
a first mirror rotating about its longitudinal axis, with a reflective surface at an acute angle to the longitudinal axis. Accordingly, a beam transmitted along the longitudinal axis may be redirected onto a second mirror
Implementation Method 2
the second reflector, which can be stationary or rotating, adjusts the beam to achieve focused, proportional dimensions on the work surface
Data Source
AI summary
A beam director for use in 3D printers comprises a first mirror rotating about its longitudinal axis for redirecting a beam onto a second mirror and then onto a work surface, which may result in a beam with a distorted shape. A beam corrector, e.g. a lens or a reflective surface, is used to ensure the beam has the same desired dimensions in the first and second perpendicular direction when striking the work surface.