Diode Laser Fiber Array Contouring for Powder Bed Fabrication
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Solution Overview
Problem
Current Direct Metal Laser Melting (DMLM) systems using one-dimensional or two-dimensional arrays of low-power lasers for powder bed fabrication or repair often result in a rough edge on the boundary of parts, detracting from surface finish and effective resolution, while being cost-inefficient compared to conventional high-power lasers.
Innovation Solution
A method and apparatus utilizing a diode laser fiber array with a plurality of diode lasers and optical fibers, where a first diode laser fiber array scans the outer boundary of the build, emitting laser beams to contour the layer, while a second diode laser fiber array fabricates the layers, improving resolution and surface finish by simultaneously melting powder along the boundary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a 1D or 2D array of low-power lasers is used for powder bed fabrication, then manufacturing cost is reduced, but surface finish and resolution deteriorate due to rough edges on part boundaries
Solution Approach 1:
The patent divides the laser system into two separate arrays: a first array for scanning and contouring the part boundaries, and a second array for filling the interior regions. This segmentation allows each array to be optimized for its specific function, with the first array using tighter spacing for high-resolution boundary work while the second array uses wider spacing for cost-effective interior fabrication.
Solution Approach 2:
The patent applies different laser spacing configurations to different regions of the part. The first diode laser fiber array uses a first spacing optimized for boundary contouring with high surface finish requirements, while the second diode laser fiber array uses a second spacing optimized for interior filling where cost-effectiveness is prioritized. This local differentiation resolves the contradiction between cost and quality.
2Device complexity
If the same laser spacing is used for both interior filling and boundary contouring, then device complexity is reduced, but manufacturing precision deteriorates due to rough boundaries
Solution Approach 1:
The patent segments the single laser array into two distinct diode laser fiber arrays with different spacing configurations. The first array is dedicated to boundary work with tighter spacing for high precision, while the second array handles interior filling with wider spacing. This segmentation resolves the contradiction by allowing different spacing optimizations for different regions without requiring a single complex variable-spacing system.
Solution Approach 2:
Each diode laser fiber array is designed to perform multiple functions: the first array contours boundaries and can also fill interior regions, while the second array fills interior regions and can supplement boundary work. This multi-functionality allows the system to maintain manufacturing precision across different part regions while managing device complexity through standardized array designs.
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 enhances the surface finish and resolution of DMLM parts, reducing manufacturing costs while maintaining quality, enabling efficient and precise contouring of powder bed layers in DMLM systems.
Implementation Method 1
emitting a plurality of laser beams from selected fibers of the first diode laser fiber array during the scanning of the first diode laser fiber array along the outer boundary of the build in the powder bed and simultaneously melting powder in the powder bed
Implementation Method 2
Direct Metal Laser Melting (DMLM) for use in the fabrication or repair of components
Data Source
AI summary
A method of forming a build in a powder bed includes providing a first diode laser fiber array and a second diode laser fiber array, emitting a plurality of laser beams from selected fibers of the second diode laser fiber array onto the powder bed, corresponding to a pattern of a layer of the build, simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build, scanning a first diode laser fiber array along an outer boundary of the powder bed and emitting a plurality of laser beams from selected fibers of the first diode laser fiber array and simultaneously melting powder in the powder bed corresponding to the outer boundary of the layer of the build to contour the layer of the build. An apparatus for forming a build in a powder bed including a first diode laser fiber array and a second diode laser fiber array is also disclosed. The first diode laser fiber array configured to contour the layer of the build.