Dynamic Optical Assembly for On-The-Fly Lens Swapping in Powder Bed Fusion
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Solution Overview
Problem
In powder bed fusion additive manufacturing, existing optical systems require shutdown and re-alignment for changes in powdered materials, leading to inefficiencies in controlling magnification ratios and image plane location, which affects imaging resolution and laser power distribution.
Innovation Solution
A dynamic optical assembly that allows for on-the-fly swapping of imaging lenses and adjustment of magnification ratios without disassembly, enabling continuous operation with different powdered materials by using a mechanical assembly with interchangeable lens sets and precise control of image distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If imaging lenses are fixed in the optical system, then the system structure is simple and stable, but the magnification ratio and image plane location cannot be adjusted when changing powdered materials
Solution Approach 1:
The patent implements a dynamic optical system where lens assemblies can be exchanged on-the-fly between different powdered materials. The system transitions from static fixed lenses to dynamic interchangeable lens assemblies, each optimized for specific material properties. This allows the optical system to adapt its magnification ratio and image plane location dynamically based on the powdered material being processed, resolving the contradiction between adaptability and complexity.
Solution Approach 2:
The optical system is segmented into multiple interchangeable lens assemblies, where each assembly is dedicated to specific powdered materials or material categories. This segmentation allows the system to switch between pre-configured lens sets rather than using a single complex adjustable lens, simplifying the overall system architecture while maintaining high adaptability to different materials.
2Manufacturing precision
If the optical system is shut down for lens re-alignment when changing materials, then imaging resolution can be maintained, but manufacturing throughput decreases
Solution Approach 1:
Each lens assembly is pre-configured and pre-aligned during manufacturing for specific powdered materials. The lens assemblies arrive at the optical system already optimized for their intended material, eliminating the need for time-consuming re-alignment operations when switching materials. This preliminary action ensures imaging resolution is maintained while enabling rapid material transitions without shutdowns.
Solution Approach 2:
The system enables continuous operation by allowing lens assembly exchanges without shutting down the additive manufacturing process. The optical system maintains continuous useful action by switching between pre-configured lens assemblies on-the-fly, ensuring that manufacturing throughput is maximized while imaging resolution is preserved through the use of pre-aligned optical components.
3Manufacturing precision
If lens assemblies are exchanged frequently to match different powdered materials, then optimal imaging and power distribution are achieved, but system availability decreases
Solution Approach 1:
The system implements a dynamic lens exchange mechanism that allows rapid switching between lens assemblies without requiring system shutdown. This dynamic capability enables the system to maintain high availability while achieving optimal power distribution and imaging for each powdered material by exchanging lens assemblies on-the-fly during operation.
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 high-resolution imaging and efficient power distribution across the print surface for various materials, maintaining system availability and improving manufacturing throughput by allowing lens swapping without shutdowns.
Implementation Method 1
an optical assembly to focus the incident light onto a print surface at an image distance
Implementation Method 2
a first lens assembly to provide a magnification ratio of the incident light containing an image information from the precursor image plane to the print surface
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A method and an apparatus of a powder bed fusion additive manufacturing system that enables a quick change in the optical beam delivery size and intensity across locations of a print surface for different powdered materials while ensuring high availability of the system. A dynamic optical assembly containing a set of lens assemblies of different magnification ratios and a mechanical assembly may change the magnification ratios as needed. The dynamic optical assembly may include a transitional and rotational position control of the optics to minimize variations of the optical beam sizes across the print surface.