Beam-Split Laser Additive Manufacturing for Parallel 3D Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current additive manufacturing methods for three-dimensional structures using light-induced chemical and/or physical processes are inefficient and costly, particularly in terms of apparatus and production costs, and lack the capability for simultaneous production of multiple identical structures.
Innovation Solution
An apparatus and method utilizing a single laser source with a focusing optical unit and a beam-splitter optical unit to split the laser beam into multiple partial beams, allowing for simultaneous manufacturing of multiple three-dimensional structures by directing each partial beam to different locations, reducing the need for multiple laser sources and simplifying the apparatus design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser sources are used to simultaneously produce multiple three-dimensional structures, then productivity is improved, but apparatus complexity and production costs increase
Solution Approach 1:
The laser beam from a single source is segmented into multiple partial beams using beam-splitter optical units. Each partial beam is then directed to a separate focusing optical unit and scanner, enabling simultaneous production of multiple structures without requiring multiple laser sources. This segmentation approach maintains productivity improvement while avoiding the complexity and cost of multiple independent laser systems.
Solution Approach 2:
A single laser source is designed to serve multiple functions by simultaneously generating multiple partial beams that each independently produce three-dimensional structures. The laser source acts as a universal energy provider for multiple manufacturing stations, reducing apparatus complexity while maintaining high productivity through multi-functional utilization of the laser system.
2Productivity
If multiple laser sources are used to simultaneously produce multiple three-dimensional structures, then productivity is improved, but production costs increase
Solution Approach 1:
By segmenting a single laser beam into multiple partial beams, the system enables simultaneous production of multiple structures using one laser source. This eliminates the need to purchase and operate multiple expensive laser sources, thereby reducing production costs while maintaining improved productivity through parallel manufacturing of multiple structures.
Solution Approach 2:
The system creates optical copies of the laser beam through beam-splitting, generating multiple identical or scaled partial beams from one source. These copied beams are then used to simultaneously manufacture multiple three-dimensional structures, reducing the cost per structure by sharing the expensive laser source across multiple production lines.
3Device complexity
If a single laser source is used with beam-splitting to produce multiple structures, then apparatus complexity is reduced, but manufacturing precision must be maintained
Solution Approach 1:
The laser beam is segmented into multiple partial beams, each assigned to its own dedicated focusing optical unit and scanner. This segmentation ensures that each partial beam maintains independent precision control through its own optical system, thereby maintaining manufacturing precision while reducing overall apparatus complexity by using a single laser source instead of multiple sources.
Solution Approach 2:
Each partial beam is equipped with its own focusing optical unit and scanner, allowing local optimization of beam quality and positioning for each specific manufacturing location. This local quality control ensures that despite the shared laser source, each three-dimensional structure receives precisely controlled laser energy tailored to its specific requirements, maintaining high manufacturing precision.
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 approach significantly reduces production costs and increases productivity by enabling the simultaneous production of multiple identical structures with a single laser source, while maintaining high quality and precision in the manufacturing process.
Implementation Method 1
at least one laser source (4) for producing a laser beam (5)
Implementation Method 2
a focusing optical unit (6) for focusing the laser beam (5) to form a laser focus (7)
Implementation Method 3
a beam-splitter optical unit (8) for dividing the laser beam (5) into at least two partial laser beams (9)
Implementation Method 4
location-selective solidification of a layer (13) of a three-dimensional structure (2) in the building surface (13) by way of light-induced chemical and/or physical processes in the material (3)
Data Source
AI summary
An apparatus for the additive manufacturing of three-dimensional structures from a material that is to be solidified by way of location-selective solidification thereof as a result of light-induced chemical and/or physical processes in the material includes a laser source for producing a laser beam, a focusing optical unit for focusing the laser beam so as to form a laser focus, and a beam-splitter optical unit for splitting the laser beam into at least two partial laser beams. The laser source, the focusing optical unit and the beam-splitter optical unit are arranged such that the laser beam, starting from the laser source, passes first through the focusing optical unit and then through the beam-splitter optical unit and the partial laser beams finally are each directed to different locations on the material that is to be solidified.