Deformable Mirror Optics for Larger, Uniform Laser Print Beds
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Solution Overview
Problem
Traditional additive manufacturing systems face limitations due to optical distortions and errors, particularly with f-theta lenses, which result in reduced build area and inconsistent material properties, forcing users to restrict the usable area and compromise on build size and quality.
Innovation Solution
The implementation of adaptive optics using a deformable mirror to impose spatially-varying phase variations in the laser beam, compensating for optical distortions and aberrations, allowing for precise control of the focused beam size and shape across the print bed, and enabling larger build areas and improved material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional f-theta lenses are used for laser focusing, then the system structure is simple, but the build area is reduced and material properties become inconsistent
Solution Approach 1:
The patent applies adaptive optics with a deformable mirror that can dynamically change its surface configuration to compensate for optical aberrations. The deformable mirror adjusts its shape in real-time based on the scan position, allowing the system to maintain consistent beam focus and material properties across the entire build area, thereby resolving the contradiction between build area and manufacturing precision.
Solution Approach 2:
The patent changes the optical parameters by introducing a deformable mirror that modifies the wavefront of the laser beam. By adjusting the mirror's surface configuration, the system compensates for field-dependent aberrations and maintains consistent focal characteristics across different positions in the build area, enabling both large build area and uniform material properties.
2Manufacturing precision
If the usable area is restricted to maintain consistent material properties, then material property consistency is improved, but the build size is reduced
Solution Approach 1:
The deformable mirror dynamically adjusts its configuration based on the current scan position, enabling the system to maintain consistent material properties across the entire build area. This dynamic compensation eliminates the need to restrict the usable area, allowing full utilization of the build platform while maintaining manufacturing precision.
Solution Approach 2:
The system uses feedback from the scan position to control the deformable mirror configuration. By continuously monitoring the scan location and adjusting the mirror accordingly, the system maintains optimal beam focus and material property consistency across the entire build area, resolving the contradiction between build size and material property consistency.
3Manufacturing precision
If adaptive optics with deformable mirror is implemented, then build area and material property consistency are improved, but the device complexity increases
Solution Approach 1:
The deformable mirror serves as an intermediary element between the laser source and the build area. It compensates for optical aberrations introduced by the f-theta lens without requiring complete redesign of the optical system. This intermediary approach enables improved material property consistency while minimizing the increase in device complexity.
Solution Approach 2:
The patent introduces a single controllable parameter - the deformable mirror configuration - to compensate for multiple optical aberrations. By controlling the mirror's surface shape, the system achieves consistent material properties across the build area with minimal additional complexity, as the mirror can be controlled through standard voltage inputs.
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 significantly increases the print area by up to 1.5-2.2 times, maintains consistent beam quality, and allows for spatially varying material properties, effectively addressing optical errors and limitations in traditional systems.
Implementation Method 1
the deformable mirror is configured to alter the wavefront of the output beam by imposing spatially-varying phase variations
Implementation Method 2
the imposed spatially-varying phase variations compensate for optical distortions associated with the f-theta lens
Implementation Method 3
the scanning mirror is configured to reflect and scan the output beam at a range of scan angles
Implementation Method 4
the f-theta lens is configured to focus the output beam onto the print bed
Implementation Method 5
a laser source configured to form an output beam... the output beam is configured to fuse the print material to form a build object
Data Source
AI summary
Systems and methods for additive manufacturing systems implementing adaptive optics in accordance with various embodiments of the invention are illustrated. One embodiment includes an additive manufacturing system including a laser source configured to form an output beam, a scanning mirror disposed in an optical path of the output beam, wherein the scanning mirror is configured to reflect and scan the output beam at a range of scan angles, a deformable mirror disposed in the optical path of the output beam, wherein the deformable mirror has a plurality of configurations for reflecting and altering a wavefront of the output beam, wherein the configuration of the deformable mirror is based on the scan angle of the scanning mirror, and a print bed configured to hold a print material, wherein the output beam is configured to fuse the print material to form a build object.