Blue Laser Optics for Large-Field High-Resolution Additive Manufacturing
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Solution Overview
Problem
Infrared (IR) based additive manufacturing systems are limited by finite build volume and build speed due to the size of the scanning system, spot creation, and low absorption of laser energy by materials, leading to restricted layer thickness and resolution.
Innovation Solution
A blue laser system with an X-Y scanning system, electronically adjustable lens, and movable optics to simulate an F-Theta lens, enabling on-the-fly focusing and improved laser beam diameter adjustment, coupled with active monitoring for precise control and higher absorptivity in materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving 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 scanning systems and spot creation
Solution Approach 1:
The patent changes the fundamental parameter of laser wavelength from infrared to visible spectrum (blue/green), which fundamentally alters the interaction with materials and enables larger build volumes while maintaining precision through different optical properties
Solution Approach 2:
The patent employs dynamically adjustable lens systems that can change focal length and spot size on-the-fly, allowing the system to adapt between large build volume requirements and high precision manufacturing needs during the same process
2Productivity
If infrared laser systems are used for additive manufacturing, then the system can operate with standard equipment, but the build speed is limited by low absorption of laser energy by materials
Solution Approach 1:
The patent changes the laser wavelength parameter to the visible spectrum where materials exhibit higher absorption coefficients, directly improving energy coupling efficiency and build speed without requiring excessive laser power
Solution Approach 2:
The patent replaces the mechanical/optical limitation of infrared systems with a fundamentally different optical approach using visible wavelength lasers, substituting the need for high power with more efficient energy absorption at different wavelengths
3Manufacturing precision
If infrared laser systems are used for additive manufacturing, then the process can proceed with conventional setups, but the layer thickness and resolution are limited by finite penetration depth
Solution Approach 1:
The patent changes the wavelength parameter to visible spectrum, which provides different penetration characteristics that enable both thin layers for high resolution and controlled deeper penetration when needed, breaking the fixed limitation of infrared systems
4Volume of moving object
If blue laser systems with adjustable lens systems are used, then the addressable field and volume are increased, but the device complexity increases
Solution Approach 1:
The patent uses dynamically adjustable lens systems that can change focal length on-the-fly, allowing a single configurable system to replace multiple fixed systems, thereby increasing addressable field without proportionally increasing overall system complexity
Solution Approach 2:
The patent creates a universal lens system that can perform multiple functions (focusing, scanning, adjusting spot size) through a single integrated adjustable optical train, reducing the need for multiple specialized components
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
The blue laser system achieves larger build volumes and faster processing speeds, with resolutions down to 75 µm, reducing the chance of run-away processes and enabling higher tolerances and reproducibility in manufacturing.
Implementation Method 1
a blue laser source capable of propagating a blue laser beam
Implementation Method 2
an electronically adjustable lens system; the lens system having a first optic, a second optic, and a third optic, wherein the second optic is movable between a plurality of positions along the laser beam path
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A high resolution system for additive manufacturing, soldering, welding and other laser processing applications. A blue laser system for additive manufacturing, soldering, welding and other laser processing applications and operation for additive manufacturing of materials.