Expanded Scan Field Optics for Gap-Free Telecentric Beam Coverage
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Solution Overview
Problem
Energy beam systems with multiple telecentric lenses suffer from gaps in the aggregate scan field due to the space occupied by their housings, limiting the irradiated area in additive manufacturing and other applications.
Innovation Solution
Incorporating flat-field lenses with scan field expansion assemblies, which include field-expanding optical elements to create overlapping scan fields, thereby closing gaps and increasing the irradiated area without requiring large lens geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple telecentric lenses are used to expand the scan field, then the irradiated area increases, but gaps appear in the aggregate scan field due to housing space occupation
Solution Approach 1:
The optical system is divided into multiple optical assemblies, each with its own telecentric lens and scan field expansion assembly. This segmentation allows independent optimization of each assembly while collectively achieving a larger continuous scan field through proper arrangement and overlap of individual scan fields.
Solution Approach 2:
The scan field expansion assembly is nested within or integrated with the optical assembly housing. The field-expanding optical elements are positioned within the existing optical path, utilizing the available space efficiently and eliminating gaps between separate housings while maintaining telecentricity.
2Stability of the object's composition
If telecentric lenses are used to maintain beam parallelism, then beam quality is improved, but the housing space required creates gaps in the aggregate scan field
Solution Approach 1:
The system uses dynamic field expansion where the scan field size is adjusted by the field-expanding optical elements in response to processing requirements. This allows the system to maintain telecentric beam parallelism while dynamically adapting the scan field coverage to eliminate gaps and maximize the irradiated area.
Solution Approach 2:
The field-expanding optical elements change the angular parameters of the energy beams while maintaining their parallelism to the optical axis. By adjusting beam angles and field coverage parameters, the system expands the aggregate scan field area without sacrificing beam quality or telecentricity.
3Area of stationary object
If larger lens geometries are used to increase scan field coverage, then the irradiated area increases, but the system complexity and size requirements become prohibitive
Solution Approach 1:
Instead of using a single large complex lens, the system segments the optical functionality into multiple standard telecentric lenses with associated field expansion assemblies. This segmentation allows use of conventional, well-understood lens designs while achieving equivalent or superior performance through systematic arrangement and field expansion.
Solution Approach 2:
The field-expanding optical elements act as intermediaries between the standard telecentric lenses and the workpiece. These intermediary elements expand the scan field without requiring the telecentric lenses themselves to be larger or more complex, thereby decoupling scan field size from lens geometry 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
This solution allows for larger areas to be irradiated in additive manufacturing and other applications, enhancing the efficiency and coverage of energy beam systems while maintaining telecentricity and reducing the need for prohibitively large lens geometries.
Implementation Method 1
The first scan field expansion assembly may include one or more first field-expanding optical elements configured to provide a first expanded scan field
Data Source
AI summary
An optical system may include a first optical assembly and a first scan field expansion assembly. The first optical assembly may include or may be configured as a first flat-field lens. The first flat-field lens may have a first nominal scan field with a first flat focal plane. The first scan field expansion assembly may include one or more first field-expanding optical elements configured to provide a first expanded scan field coinciding with the first flat focal plane. The first expanded scan field may have a cross-sectional width and/or area that exceeds a corresponding cross-sectional width and/or area of the first nominal scan field. A method of additively manufacturing a three-dimensional object may include directing a first energy beam through the first optical assembly, and directing the first energy beam through the first scan field expansion assembly.