3D Direct Write Laser Patterning Doubly-Curved Surfaces
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Solution Overview
Problem
Existing methods for creating electrical circuits on curved surfaces, such as those in aerospace and defense applications, face challenges with discontinuous patterns, registration issues in multilayered designs, and limitations in handling extreme temperatures and complex geometries, particularly in radome structures where high precision and continuous patterns are required.
Innovation Solution
A three-dimensional direct write system utilizing an ablative or actinic light source and multi-axis galvanometer scan system with software-generated three-dimensional vector data, capable of scanning a single focused beam of light across curved surfaces with high precision and speed, eliminating the need for translational movement of conventional machine tools and allowing for seamless patterning on both external and internal surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flat sheets of etched conductors are spliced onto curved surfaces, then the circuit can be applied to curved surfaces, but the pattern is not continuous and gaps are present at the joints
Solution Approach 1:
The patent replaces mechanical splicing of flat conductor sheets with a direct-write laser system that deposits conductive material directly onto the curved surface in a continuous pattern. The laser beam is steered using galvanometer mirrors to trace the desired circuit path, eliminating mechanical joints and gaps while maintaining pattern continuity on complex curved surfaces.
Solution Approach 2:
The invention transitions from two-dimensional flat conductor sheets to three-dimensional direct writing on curved surfaces. The laser beam moves in three-dimensional space to deposit material along the surface curvature, enabling continuous patterns that conform to the surface geometry without requiring flat sheet splicing.
2Manufacturing precision
If photolithography is used to transfer patterns onto three-dimensional surfaces, then seam free patterns can be produced, but the speed is limited by the multi-axis robot positioning system
Solution Approach 1:
The patent replaces the slow multi-axis robot positioning system with a high-speed laser direct-write system controlled by galvanometer mirrors. The galvanometers can rapidly steer the laser beam across the surface at speeds much faster than mechanical robot movement, dramatically increasing patterning speed while maintaining precision through software-controlled beam positioning.
Solution Approach 2:
The system uses periodic scanning motion of the laser beam across the surface, with the galvanometer mirrors oscillating at high frequencies to rapidly trace the circuit pattern. This periodic scanning action enables much faster material deposition compared to the continuous slow movement of a multi-axis robot.
3Manufacturing precision
If photolithography is used for patterning, then precise patterns can be formed, but projection errors cause distortion and element size changes on three-dimensional surfaces
Solution Approach 1:
The patent replaces optical projection with direct laser writing, eliminating projection errors entirely. The laser beam is positioned directly at the target location on the curved surface using galvanometer-controlled steering, ensuring that the deposited pattern dimensions match the design specifications without distortion from optical projection through air or lenses.
Solution Approach 2:
The system introduces software-generated three-dimensional vector data as an intermediary between the design and the physical pattern. The software calculates the precise laser beam trajectory and deposition parameters to compensate for surface curvature, ensuring uniform element sizes and accurate pattern geometry without optical projection distortion.
4Manufacturing precision
If conventional machine tools are used for patterning, then precise control is possible, but translational movement is required which reduces speed
Solution Approach 1:
The patent replaces conventional machine tools with translational movement with a laser direct-write system using galvanometer mirrors. The galvanometers rotate to steer the laser beam in two dimensions, replacing slow mechanical table movement with rapid angular mirror rotation, achieving both high precision and high speed patterning.
Solution Approach 2:
The system uses dynamic galvanometer mirror rotation to rapidly reposition the laser beam across the surface. Instead of moving the entire machine tool or table, the lightweight mirrors rotate dynamically to change beam direction instantaneously, enabling high-speed scanning while maintaining precise positioning control through feedback systems.
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
Enables rapid and precise patterning of large areas with continuous, rotationally symmetric, or arbitrary-shaped patterns on various materials, including photoimageable polymers and ceramic films, without the need for photomasks, and effectively addresses the limitations of prior art by maintaining electrical conductivity and withstanding high temperatures.
Implementation Method 1
optical system in relation to the substrate, the optical system operative for projecting a focal point of light to different points of the doubly-curved surface
Implementation Method 2
A three-dimensional direct write system capable of defining a plurality of elements across a large field of view using an ablative or actinic light source
Data Source
AI summary
Disclosed is a system and method for patterning internal and/or external doubly-curved surfaces by use of a light source, three-dimensional scanning optics, computer controller, and a multi-axis robot. The system is capable of digitally receiving shape, location, and pattern data of a three-dimensional doubly-curved surface and applying said pattern over large areas with high precision in a seamless fashion.