DED Laser Beam Scanning for Wide Thin Metal Traces

The patent applies dynamics by moving the laser beam dynamically during translation to create a time-varying power distribution pattern. The laser beam is oscillated or scanned in a direction transverse to the translation direction, creating a dynamic melting pattern that produces a wide yet thin trace. This dynamic movement allows the laser to cover a larger area (increasing productivity) while maintaining control over the melt pool depth through the temporal variation of energy input.

The patent changes the power distribution parameters by varying the laser beam position dynamically during translation. By modulating the laser beam's transverse position and/or power output, the system creates a non-uniform power distribution across the trace width. This parameter change enables independent control of trace width and depth, allowing wide traces for productivity while maintaining shallow depth for resolution.

The patent makes the single additive-manufacturing head multi-functional by equipping it with dynamic laser beam control capabilities. The same head that deposits powder also dynamically directs the laser beam to create complex power distributions. This universal head performs both material deposition and sophisticated thermal processing, eliminating the need for multiple specialized heads while achieving the same geometric control.

The patent introduces dynamic laser beam direction control within the single head, allowing one head to perform the function of multiple heads. By dynamically oscillating or scanning the laser beam during translation, a single head can create wide, thin traces that would otherwise require multiple coordinated heads, thereby reducing system complexity while maintaining precision.

The patent transforms the stationary laser beam into a dynamic one by implementing beam oscillation or scanning mechanisms. The laser beam is moved dynamically in a direction transverse to the translation direction, creating a time-varying power distribution. This dynamic approach decouples trace width control from focusing spot size, as the effective trace width is determined by the beam's dynamic path rather than its static size, providing greater process flexibility.

The patent employs periodic action by oscillating the laser beam back and forth during translation. This periodic movement creates a characteristic power distribution pattern that controls both trace width and depth independently. The oscillation frequency and amplitude can be adjusted to achieve different trace geometries, providing versatile control without increasing fundamental system complexity.