Dome-Shaped Lasing Module for Higher-Throughput 3D Printing
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Solution Overview
Problem
Existing additive manufacturing processes face challenges with long print times, low throughput, and lack of robustness, stability, and repeatability compared to conventional manufacturing processes.
Innovation Solution
A 3D printing system with a dome-shaped lasing module that packs multiple lasers vertically above the build area, using mirrors and lenses to steer laser beams individually and adjust spot size, combined with imaging sensors for feedback, to enhance precision and repeatability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple lasers are packed vertically above the build area in a dome-shaped structure, then productivity and throughput are improved, but device complexity increases
Solution Approach 1:
The patent transitions from a traditional horizontal arrangement of lasers to a vertical dome-shaped configuration. Multiple lasers are positioned at different heights and angles above the build area, utilizing the vertical dimension to increase laser density without expanding the horizontal footprint. This dimensional change enables higher productivity while managing device complexity through spatial optimization.
Solution Approach 2:
The patent employs a dome-shaped structure to house multiple lasers, replacing flat or linear arrangements with a curved, spherical geometry. This spheroidal configuration allows lasers to be distributed uniformly across the dome surface, optimizing their angular positions for melting powder from multiple directions simultaneously, thereby enhancing manufacturing speed and throughput.
2Manufacturing precision
If mirrors and lenses are used to steer laser beams and adjust spot size individually, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent divides the optical system into individual controllable units, with each laser equipped with its own mirrors and lenses for beam steering and spot size adjustment. This segmentation allows independent optimization of each laser's parameters, enabling precise control over melting characteristics and improving manufacturing precision while managing complexity through modular design.
Solution Approach 2:
The patent implements dynamic control of optical components, where mirrors and lenses can be adjusted in real-time to steer laser beams and modify spot sizes. This dynamic adaptability allows the system to optimize laser parameters for different build positions and material requirements, enhancing manufacturing precision through active control mechanisms.
3Reliability
If imaging sensors are added for feedback control, then reliability and repeatability are improved, but device complexity increases
Solution Approach 1:
The patent incorporates imaging sensors that capture real-time data from the build area and feed this information back to the control system. This feedback mechanism enables monitoring and adjustment of the laser melting process, ensuring consistent quality and improving reliability and repeatability by detecting and correcting deviations from desired parameters.
Solution Approach 2:
The patent replaces manual or mechanical control methods with automated optical sensing and electronic feedback systems. Imaging sensors and digital control algorithms substitute for mechanical adjustment mechanisms, providing more precise and reliable control over the laser processing parameters, thereby enhancing repeatability while reducing mechanical 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
The system achieves improved manufacturing speed, accuracy, precision, stability, and repeatability, with increased throughput and redundancy, enabling efficient and reliable part production.
Implementation Method 1
The lasing module may include a plurality of lasers for melting powdered metal within or on the build modules
Implementation Method 2
lasers that generate the laser beams for melting powdered metal disposed in the build module
Implementation Method 3
The optical modules include various lens(es) and/or mirror(s) for steering laser beams towards the powdered metal, as well as imaging sensor(s) for imaging (e.g., melt pool) during the printing process
Data Source
AI summary
A 3D printing system uses lasers for manufacturing parts in metal additive manufacturing, such as powder-bed fusion. The lasers may be arranged on a dome-shaped structure, vertically above powdered metal. The dome-shaped structure, and arrangement of the lasers on the dome-shaped structure, permits a higher density of the lasers to be packaged onto the 3D printing system and increases a utilization of the lasers during manufacturing. Mirror(s) allow the lasers to be selectively, and individually, steered towards particular locations within the powdered metal in which the parts are manufactured. Lens(es) may actuate to adjust a spot size of laser beams emitted by the lasers. Imaging sensor(s) may also monitor the powdered metal, such as a melt pool of the powdered metal, for feedback and use in driving and steering the lasers.