Blue Laser Additive Manufacturing for Larger Builds at Fine Spot Size
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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 low material absorptivity for infrared wavelengths, leading to restricted layer thickness and resolution.
Innovation Solution
A blue laser system with an electronically adjustable lens system and X-Y scanning capability, capable of focusing and adjusting the laser beam on the fly, is used to achieve higher absorptivity and larger addressable areas, allowing for improved coupling of laser energy into materials and increased build volume and speed.
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 scanning systems and spot size
Solution Approach 1:
The patent changes the wavelength parameter of the laser from infrared to visible spectrum (400-700 nm). This parameter change enables the use of shorter focal length optics, which increases the addressable field size while maintaining the same spot size, thereby expanding build volume without sacrificing manufacturing precision.
Solution Approach 2:
The patent transitions from infrared to visible wavelength regime, which represents a dimensional change in the electromagnetic spectrum. This transition fundamentally alters the optical properties and enables different scaling relationships between spot size and addressable field, allowing simultaneous improvement in both build volume and resolution.
2Productivity
If infrared laser systems are used for additive manufacturing, then the system can operate with standard infrared lasers, but the build speed is limited by low material absorptivity and finite penetration depth
Solution Approach 1:
The patent changes the laser wavelength parameter from infrared to visible spectrum. This parameter change exploits the fact that most materials have higher absorptivity in the visible range, reducing energy reflection and improving coupling efficiency. The result is faster processing speeds and reduced energy waste.
3Area of stationary object
If infrared laser systems are used with fixed focal length optics, then the optical system is simple, but the addressable field size is limited
Solution Approach 1:
The patent changes the wavelength parameter to visible spectrum, which enables the use of shorter focal length optics. This parameter change allows the system to achieve a larger addressable field size with simpler, shorter focal length lenses compared to infrared systems that require long focal lengths to achieve the same spot size.
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 enhances build volume and speed by achieving twice the addressable area of IR systems with the same spot size, enabling the creation of larger parts with higher resolution and reduced power consumption, while maintaining control and reproducibility.
Implementation Method 1
Most raw build materials have a modest to low reflectivity for wavelengths in the infrared spectrum. As a consequence, the coupling of the infrared laser energy into the raw build materials, e.g., powder bed or particles, is limited with a significant portion of the energy being reflected away
Data Source
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. Systems and methods for laser processing of materials, laser processing by matching preselected laser beam wavelengths to the material to be processed to have high or increased levels of absorptivity by the materials, and in particular laser additive manufacture of raw materials into large structures, parts, components and articles with laser beams having high absorptivity by starting raw materials.