Blue Laser Additive Manufacturing With DMD Beam Patterning
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Solution Overview
Problem
Infrared (IR) based additive manufacturing systems face limitations in build volume and speed due to finite scanning systems and high reflectivity of metals, leading to inefficient energy coupling and resolution issues.
Innovation Solution
The use of a laser source with a Digital Mirror Device (DMD) and spatial light modulators to project a laser beam in a predetermined pattern onto a powder bed, optimizing wavelengths between 300-800 nm for improved absorptivity and energy efficiency, and employing a conduction mode welding process to fuse metal powders without keyhole welding, which reduces spatter and enhances resolution and build speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If infrared laser beams are used for additive manufacturing, then the process can be implemented with existing IR laser systems, but the build volume is limited by finite scanning systems and spot size
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 metal materials. This parameter change enables both larger build volumes and improved spot quality simultaneously, resolving the contradiction between build volume and manufacturing precision.
Solution Approach 2:
The patent replaces the mechanical scanning system limitations with a different optical approach using visible wavelength lasers that can be focused to smaller spots and penetrate deeper into materials, effectively substituting the constrained IR mechanical scanning approach with a more flexible visible light optical system.
2Use of energy by moving object
If infrared laser beams are used to process metals, then the process can be applied to metal materials, but energy coupling is inefficient due to high IR reflectivity
Solution Approach 1:
The patent changes the laser wavelength parameter from infrared to visible spectrum (blue 450nm or green 532nm), which fundamentally changes how the laser energy interacts with metal surfaces. Visible wavelength lasers are absorbed much more efficiently by metals like copper, aluminum, and gold, eliminating the high reflectivity problem that plagues IR laser processing of these materials.
3Productivity
If infrared laser systems are used, then the system can operate at standard IR wavelengths, but build speed is limited by energy absorption constraints
Solution Approach 1:
By changing the laser wavelength from infrared to visible spectrum, the patent achieves dramatically improved energy absorption in metal materials. This allows for higher power densities to be delivered to the material, enabling faster melting and solidification rates, thus increasing build speed without sacrificing energy coupling efficiency.
4Manufacturing precision
If infrared laser beams are used, then the process can be implemented with current technology, but resolution is limited by finite penetration depth
Solution Approach 1:
The patent changes the laser wavelength to visible spectrum, which enables both deeper penetration into metal materials and tighter focusing to smaller spot sizes. This dual benefit allows for higher resolution processing with controlled penetration depth, overcoming the resolution limitations of IR systems while maintaining appropriate energy coupling.
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 higher resolution, faster build rates, and improved quality by enhancing energy absorption and reducing defects, allowing for the production of complex metal parts with increased precision and efficiency.
Implementation Method 1
optimizing wavelengths between 300-800 nm for improved absorptivity
Implementation Method 2
laser source with a Digital Mirror Device (DMD) and spatial light modulators to project a laser beam
Implementation Method 3
Digital Mirror Device (DMD) and spatial light modulators to project a laser beam in a predetermined pattern
Implementation Method 4
employing a conduction mode welding process to fuse metal powders without keyhole welding
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.