Blue Laser Module Combining for High-Absorption Metal Processing
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Solution Overview
Problem
Infrared-based additive manufacturing systems face limitations in build volume and speed due to their wavelength and power constraints, necessitating the development of high-power blue and green lasers for improved materials processing.
Innovation Solution
The development of high-power blue laser diode systems that launch over 100 Watts into a 50 to 200 μm fiber, with beam parameter products of 5 to 10 mm-mrad, capable of spectrally combining beams to pump Raman fiber lasers for materials processing, including welding, cutting, and 3D printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If infrared-based additive manufacturing systems are used, then the systems can process materials with current technology, but the build volume and build speed are limited
Solution Approach 1:
The patent changes the fundamental parameter of laser wavelength from infrared to blue/green spectrum, enabling higher optical absorption in metals and thus achieving higher power delivery and improved build speed while overcoming the power limitations of IR systems
2Volume of moving object
If infrared-based additive manufacturing systems are used, then the systems can operate with existing infrastructure, but the build volume is limited
Solution Approach 1:
The patent changes the laser wavelength parameter to blue/green spectrum which enables higher power delivery through improved optical absorption, directly enabling larger build volumes that were previously unachievable with IR laser power limitations
3Productivity
If high power blue laser diode systems are developed, then materials processing efficiency is improved with high optical absorption, but the device complexity increases
Solution Approach 1:
The patent segments the blue laser system into multiple independent laser diode bars that can be operated separately and combined, allowing complex high-power functionality to be achieved through modular assembly rather than a single complex component
Solution Approach 2:
The patent combines multiple blue laser diode bars with individual cooling channels into a unified system that achieves high power output while maintaining manageable complexity through systematic integration of identical modular units
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
These systems enable efficient materials processing and welding with high optical absorption in the blue region, overcoming limitations of IR lasers, and provide scalable, high-power blue laser systems for various applications.
Implementation Method 1
high-power blue laser diode systems that launch >100 Watts into a 50 to 200 μm fiber
Implementation Method 2
capable of spectrally combining beams to pump Raman fiber lasers
Data Source
AI summary
The invention may be embodied in other forms than those specifically disclosed herein without departing from itMulti-kW-class blue (400-495 nm) fiber-delivered lasers and module configurations. In embodiments, the lasers propagate laser beams having beam parameter products of <5 mm*mrad, which are used in materials processing, welding and pumping a Raman laser. In an embodiment the laser system is an integration of fiber-coupled modules, which are in turn made up of submodules. An embodiment has sub-modules having a plurality of lensed blue semiconductor gain chips with low reflectivity front facets. These are locked in wavelength with a wavelength spread of <1 nm by using volume Bragg gratings in an external cavity configuration. An embodiment has modules having of a plurality of submodules, which are combined through wavelength multiplexing with a bandwidth of <10 nm, followed by polarization beam combining. The output of each module is fiber-coupled into a low NA fiber. In an embodiment a kW-level blue laser system is realized by fiber bundling and combining multiple modules into a single output fiber.