Dry Beam Path for Additive Manufacturing
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Solution Overview
Problem
The increasing demand for high-precision series production in additive manufacturing poses challenges due to the sensitivity of optical components to fumes, contamination, and temperature fluctuations, particularly when using laser radiation, which affects the precision and accuracy of the manufacturing process.
Innovation Solution
The implementation of an additive manufacturing method and device that maintains a defined gas atmosphere with relative humidity below 3% in the optical space, using a CO laser and humidity control systems like drying devices or gas mixtures to minimize water vapor absorption and scattering of laser radiation, ensuring precise laser beam delivery and improved optical component protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If optical components are exposed to the process chamber environment, then the device complexity is reduced, but the manufacturing precision deteriorates due to sensitivity to fumes, contamination, and temperature fluctuations
Solution Approach 1:
The optical system is segmented into a separate optical chamber that is physically isolated from the process chamber. This segmentation allows the optical components to operate in a controlled environment while the process chamber handles the manufacturing operations, thereby maintaining precision without excessive complexity.
Solution Approach 2:
A defined gas atmosphere acts as an intermediary medium between the optical components and the external environment. By controlling the gas composition and humidity in the optical chamber, the system protects sensitive optical components from contamination and thermal fluctuations while allowing laser radiation to pass through effectively.
2Manufacturing precision
If the optical space is hermetically sealed to protect components, then the manufacturing precision is maintained, but the ease of operation deteriorates due to difficulty in accessing and maintaining optical components
Solution Approach 1:
Optical components are extracted from the process chamber and placed in a separate optical chamber. This extraction allows the optical system to be maintained and adjusted independently without exposing it to the harsh process environment, while still maintaining the benefits of a controlled atmosphere for precision operation.
3Power
If relative humidity is reduced below 3% to minimize water vapor absorption, then the power of laser radiation is improved, but the device complexity increases due to humidity control systems
Solution Approach 1:
A defined gas atmosphere with controlled humidity is created in the optical chamber to minimize water vapor absorption of laser radiation. By maintaining low humidity conditions, the system preserves laser power and efficiency while the gas composition is optimized for the specific laser wavelength used.
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 precision and power of laser radiation by reducing water vapor absorption, allowing for more accurate and efficient production of high-precision components, particularly suitable for polymer-based materials, by maintaining a controlled gas environment that minimizes beam interference and maintains the integrity of optical components.
Implementation Method 1
water vapor absorption and scattering of laser radiation
Data Source
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AI summary
An additive manufacturing process for producing a three-dimensional object (2) in an additive manufacturing device (1) by selectively solidifying build-up material (13) layer by layer by means of laser irradiation, wherein: in a process chamber (3) a build-up material layer is repeatedly applied to a previously selectively solidified build-up material layer and is scanned with the laser radiation at locations corresponding to the cross-section of the object in this layer, the laser radiation is generated with a laser light source (21) and directed onto the build-up material layer via a number of optical components, wherein the optical components are housed in an optics space enclosed by an optics space enclosure (20a), is characterized in that a defined gas atmosphere is maintained within the optics space, wherein the relative humidity of the defined gas atmosphere is kept below 3%.