Blue Laser Powder Bed Fusion With DMD Pattern Projection
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Solution Overview
Problem
Infrared (IR) based additive manufacturing systems face limitations in build volume and speed due to finite scanning system sizes and high reflectivity of metals, leading to inefficient energy coupling and resolution constraints.
Innovation Solution
The use of a laser source with a Digital Mirror Device (DMD) to project a working laser beam in a predetermined pattern onto a powder bed, allowing for high absorptivity and efficient energy coupling, particularly using blue laser beams with wavelengths between 400-500 nm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If infrared laser systems are used for additive manufacturing, then the process can be implemented with existing technology, but the build volume is limited by the finite size of the scanning systems and spot size
Solution Approach 1:
The patent changes the wavelength parameter of the laser from infrared to blue laser (400-500 nm), which fundamentally alters the interaction with metal materials. This parameter change enables much smaller spot sizes (10-50 micrometers) while maintaining or expanding build volume, resolving the contradiction between build volume and manufacturing precision.
2Productivity
If infrared laser systems are used for additive manufacturing, then the system can process materials, but the build speed is limited by high reflectivity of metals causing inefficient energy coupling
Solution Approach 1:
The patent changes the laser wavelength parameter from infrared to blue laser (400-500 nm), exploiting the fact that blue light is strongly absorbed by metals while infrared is reflected. This parameter change dramatically reduces energy loss through reflection and enables much faster processing speeds, directly resolving the contradiction between productivity and energy loss.
3Manufacturing precision
If infrared laser systems are used for additive manufacturing, then the process can be implemented, but the resolution is limited by finite penetration depth of infrared laser light
Solution Approach 1:
The patent changes the laser wavelength from infrared to blue laser (400-500 nm), which has much shorter penetration depth in metals. This enables precise control of energy deposition at shallow depths, achieving higher resolution and more accurate feature definition while maintaining efficient energy utilization.
4Manufacturing precision
If infrared laser systems are used for additive manufacturing, then the system can operate with standard equipment, but the layer thickness is limited determining optimum layer thickness and resolution
Solution Approach 1:
The patent changes the laser wavelength to blue laser (400-500 nm), which enables much thinner layer processing (10-50 micrometers) due to shorter penetration depth and smaller spot size. This parameter change allows for higher resolution layers without requiring complex system reconfiguration, as the blue laser inherently provides the necessary 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 enables increased build speed and resolution, improved energy efficiency, and reduced defects such as spatter and porosity, by effectively fusing metal powders with high absorptivity to the laser energy.
Implementation Method 1
high absorptivity and efficient energy coupling, particularly using blue laser beams with wavelengths between 400-500 nm
Implementation Method 2
fusing metal powders with high absorptivity to the laser energy
Implementation Method 3
fusing metal powders
Data Source
AI summary
A high-resolution additive manufacturing system and method using a Digital Mirror Device and having image segments that make up an image of an entire object and are projected to the target area to deliver a working laser beam in the image of the entirety of the object to be built. A method and system for additive manufacturing using a DMD in the laser beam path. The use of a pre-heat laser beam in combination with a build laser beam having a DMD along the build laser beam path.