Demagnifying Telescope Layout for Precise Powder Bed Laser Imaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing systems using Powder Bed Fusion (PBF-AM) require expensive and complex corrective optics to accurately pattern the powder bed, which increases costs and complexity.
Innovation Solution
The system incorporates an XY gantry mirror system, an XY galvo mirror system, a demagnifying telescope, and an image relay telescope to redirect and focus two-dimensional laser images onto a print bed, reducing the need for corrective optics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If corrective optics are used to accurately pattern the powder bed, then print quality is improved, but system cost and complexity increase
Solution Approach 1:
The patent extracts and eliminates the need for complex corrective optics by using a galvanometer mirror system that directly patterns the powder bed through software-controlled mirror deflections. This removes the problematic corrective optics component while maintaining print quality through alternative means (galvo mirror precision control).
Solution Approach 2:
The patent replaces the mechanical corrective optics system with an electro-optical galvanometer mirror system. The galvanometer mirrors use electromagnetic fields to control mirror deflection angles, substituting complex mechanical optical correction with electronically controlled mirror positioning that achieves the same patterning function with reduced complexity.
2Manufacturing precision
If corrective optics are used to accurately pattern the powder bed, then print quality is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the need for expensive corrective optics by using a galvanometer mirror system that directly patterns the powder bed through software-controlled mirror deflections. This removes the costly corrective optics component while maintaining print quality through alternative means (galvo mirror precision control).
Solution Approach 2:
The patent employs galvanometer mirrors which are relatively inexpensive compared to precision corrective optics. The galvo mirrors can be easily replaced if needed and provide sufficient precision for powder bed patterning without requiring the expensive, complex corrective optical elements that would increase manufacturing cost.
3Area of stationary object
If XY gantry system is used to redirect laser image, then coverage area is improved, but system complexity increases
Solution Approach 1:
The patent segments the laser patterning function into two independent systems: an XY gantry system for positioning and a galvanometer mirror system for fine patterning control. This segmentation allows each subsystem to be optimized independently, reducing overall system complexity while maintaining full print bed coverage capability.
Solution Approach 2:
The XY gantry system serves multiple functions: it positions the laser across the entire print bed area and coordinates with the galvanometer mirrors to achieve both broad coverage and precise patterning. This multi-functionality reduces the need for additional specialized components, thereby managing system complexity.
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 configuration enhances print quality while reducing the number and expense of corrective optics, leading to more efficient and cost-effective additive manufacturing processes.
Implementation Method 1
a first demagnifying telescope capable of forming an image is positioned between the XY gantry mirror system and the XY galvo mirror system
Implementation Method 2
a second image relay telescope is positioned between the first demagnifying telescope and the XY galvo
Implementation Method 3
a second image relay telescope is positioned between the first demagnifying telescope and the XY galvo
Implementation Method 4
uses one or more focused lasers to draw a pattern in a thin layer of powder by melting the powder and bonding it to the layer below
Implementation Method 5
by melting the powder and bonding it to the layer below
Data Source
AI summary
A print engine of an additive manufacturing system can include a XY gantry mirror system arranged to receive and redirect a two dimensional laser image. An XY galvo mirror system can be arranged to receive and redirect the two dimensional laser image from the XY gantry mirror system toward multiple positions on a print bed following a print path. A first demagnifying telescope capable of forming an image is positioned between the XY gantry mirror system and the XY galvo mirror system and a second image relay telescope is positioned between the first demagnifying telescope and the XY galvo.