Diode Array Powder Bed Fusion Without Raster Scanning
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Solution Overview
Problem
Conventional Additive Manufacturing (AM) processes using metal powders are slow due to the need for raster scanning, which limits part size and production time, especially when creating metal objects.
Innovation Solution
A system utilizing a high power diode array and a digitally controlled mask to generate a pulsed laser beam with adjustable power density, allowing for simultaneous melting or sintering of entire layers of powdered material, eliminating the need for raster scanning and enabling larger part sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a laser beam is rastered along the powder surface to make two-dimensional sections, then the part is formed layer by layer, but the manufacturing time becomes excessively long (2-3 hours for machining vs. 8+ hours for AM)
Solution Approach 1:
The laser beam is segmented into multiple independent beams arranged in a grid pattern, allowing simultaneous processing of multiple locations across the powder bed rather than sequential raster scanning. This segmentation enables parallel fabrication of layer sections, dramatically reducing manufacturing time while maintaining precision through independent control of each beam.
Solution Approach 2:
The system transitions from one-dimensional raster scanning to two-dimensional parallel beam arrays. By arranging laser beams in a grid configuration that covers the entire build area, the system processes multiple points simultaneously across the surface, effectively adding a spatial dimension to the manufacturing process and eliminating the time-consuming back-and-forth raster motion.
2Strength
If a high power laser beam is used to melt metallic powder, then the material is fused into desired shapes, but the maximum part size is limited (25 cm×25 cm area)
Solution Approach 1:
The single high-power laser beam is divided into multiple lower-power beams arranged in a grid, allowing the processing area to be extended beyond the limitations of a single beam while maintaining effective fusion quality at each location. Each beam independently melts and fuses powder in its designated zone, enabling larger build areas through parallel processing.
Solution Approach 2:
Multiple laser beams are combined in a grid configuration to collectively cover a larger area than a single beam could achieve. The beams work in parallel, with each contributing to the overall layer formation, thereby merging their individual processing zones into a larger effective build area while maintaining the material fusion quality of individual high-power beams.
3Device complexity
If a single laser beam is used for additive manufacturing, then the system is simpler, but the manufacturing time increases significantly due to raster scanning requirements
Solution Approach 1:
The single laser beam is segmented into multiple beams that operate simultaneously across the build area. This segmentation eliminates the need for time-consuming raster scanning by allowing parallel processing of multiple locations, dramatically reducing manufacturing cycle time while maintaining relative system simplicity through the use of array-based laser sources and fixed optical paths.
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
Significantly reduces the time required to manufacture metal objects by allowing for single-pass layer formation, increasing efficiency and scalability while maintaining precise control over the manufacturing process.
Implementation Method 1
An optical subsystem may be included which is configured to receive the laser beam and to generate an optical signal comprised of electromagnetic radiation sufficient to melt or sinter the powdered material
Implementation Method 2
a laser for generating a laser beam... A specific one of the different power density levels may be selectable based on a specific material composition of the powdered material
Data Source
AI summary
The present disclosure relates to a system for performing an Additive Manufacturing (AM) fabrication process on a powdered material, deposited as a powder bed and forming a substrate. The system makes use of a laser for generating a laser beam, and an optical subsystem. The optical subsystem is configured to receive the laser beam and to generate an optical signal comprised of electromagnetic radiation sufficient to melt or sinter the powdered material. The optical subsystem uses a digitally controlled mask configured to pattern the optical signal as needed to melt select portions of a layer of the powdered material to form a layer of a 3D part. A power supply and at least one processor are also included for generating a plurality of different power density levels selectable based on a specific material composition, absorptivity and diameter of the powder particles, and a known thickness of the powder bed. The powdered material is used to form the 3D part in a sequential layer-by-layer process.