Fiber Array Multi-Beam Shaping for Metal Additive Manufacturing
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Solution Overview
Problem
Existing laser power sources for metal additive manufacturing lack active and adaptive control of spatiotemporal laser beam characteristics and appropriate in situ sensing techniques, limiting process control and product quality.
Innovation Solution
An additive manufacturing system utilizing a laser beam scanning matrix with micro scanner modules, a fiber laser source, and in situ sensing systems, enabling adaptive multi-beam shaping and real-time process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single laser beam is used for metal additive manufacturing, then the system is simple to operate, but productivity is low due to sequential processing
Solution Approach 1:
The single laser beam is segmented into multiple independent beams using a beam splitter array, allowing simultaneous processing of multiple locations on the powder bed. Each beam can be independently controlled to process different regions, thereby increasing productivity while maintaining manageable system complexity through modular beam control
Solution Approach 2:
Multiple laser beams are combined into a single optical path using beam combining optics, enabling simultaneous delivery of multiple beams to different locations on the build platform. This merging approach increases productivity by parallel processing while consolidating the optical system into a manageable configuration
2Manufacturing precision
If laser beam parameters are fixed, then the system is easy to control, but manufacturing precision is limited due to inability to adapt to varying material properties
Solution Approach 1:
The laser beam parameters (power, focus, spot size) are made dynamically adjustable during the manufacturing process. Each beam's parameters can be independently modified in real-time based on material properties and processing requirements, enabling precise energy deposition control while adapting to varying conditions throughout the build process
Solution Approach 2:
The system enables independent adjustment of multiple beam parameters including power, focal position, and spot diameter for each individual beam. These parameter changes allow optimization of laser energy deposition for different materials and processing stages, improving manufacturing precision without requiring complex manual intervention
3Reliability
If no in situ sensing is implemented, then the system is simple, but reliability is reduced due to lack of real-time process monitoring
Solution Approach 1:
In situ sensors are integrated into the laser processing system to provide real-time feedback on material properties, melt pool characteristics, and process conditions. This feedback is used to dynamically adjust laser beam parameters, ensuring consistent and reliable manufacturing outcomes while maintaining automated control without excessive 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 productivity, repeatability, and quality in metal additive manufacturing by enabling precise control of laser energy deposition and material processing.
Implementation Method 1
a laser beam scanning element operable to selectively change the position of the fiber tip or the lens in at least two dimensions
Implementation Method 2
a fiber laser source operable to selectively provide laser power to the fiber tips of the plurality of micro scanner modules
Implementation Method 3
use the laser to heat the metal powder in a desired pattern so that it melts
Implementation Method 4
a lens positioned on an optical axis of the fiber tip
Data Source
AI summary
A system that uses a scalable array of individually controllable laser beams that are generated by a fiber array system to process materials into an object. The adaptive control of individual beams may include beam power, focal spot width, centroid position, scanning orientation, amplitude and frequency, of individual beams. Laser beam micro scanner modules (MSMs) are arranged into 2D arrays or matrices. During operation of the MSMs, a fiber tip that projects the laser beam is displaced along the x and y-axis in order to scan the focal spot. Each MSM within a matrix can process a corresponding cell (e.g., one square centimeter) during focal spot scanning, and the plurality of MSMs may be operated in parallel to process a plurality of corresponding cells (e.g., with a 10×10 matrix of MSM, 100 cm2) without rastering or otherwise repositioning the assembly over the build surface.