Fiber-Coupled Laser Beam Scanning for Multi-Laser Powder Bed Coverage
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Solution Overview
Problem
Current multi-laser additive manufacturing systems face limitations due to the high cost, complexity, and physical constraints of aligning multiple beam delivery channels, which restrict the number of lasers that can be used effectively over a powder bed, impacting the speed and efficiency of the additive manufacturing process.
Innovation Solution
A laser beam scanner utilizing a plurality of optical fibers and a fibre termination optic, where the laser beams positioning optic is movable relative to the fibre termination optic to scan the beams across a working surface, allowing for increased laser power delivery and rapid dynamic response without the need for individual optical channels for each laser, and using a contoured termination optic to align and focus the beams efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple beam delivery channels are used to increase laser power delivery, then the speed and efficiency of additive manufacturing is improved, but the cost and complexity of the system increases due to requiring multiple galvo-mirrors and focusing components for each laser
Solution Approach 1:
The patent combines multiple laser beams into a single optical channel by using a beam combining optic that receives multiple laser beams and directs them through a shared optical path to the powder bed, eliminating the need for separate beam delivery channels for each laser
Solution Approach 2:
The shared optical channel serves multiple functions by delivering multiple laser beams simultaneously to different locations on the powder bed, allowing a single optical path to perform what previously required multiple separate channels
2Area of stationary object
If multiple beam delivery channels are used to deliver laser power to different areas, then the coverage area is improved, but the physical space required for the system increases due to the size of individual optical channels
Solution Approach 1:
The patent uses a scanning mechanism that moves the combined laser beams across the powder bed in two dimensions, allowing a single optical channel to cover a large area by dynamically positioning the beams rather than requiring fixed optical paths to multiple locations
3Manufacturing precision
If individual optical channels are used for each laser, then the precision of laser delivery is improved, but the alignment and servicing time increases
Solution Approach 1:
The patent merges multiple laser beams into a single optical channel using a beam combining optic, which reduces the number of alignment interfaces from multiple separate channels to a single shared path, thereby simplifying alignment and servicing while maintaining positioning precision through the scanning mechanism
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 enables high-efficiency laser power delivery to the powder bed with minimal energy loss, allowing for faster and more agile scanning, thereby enhancing the speed and cost-effectiveness of the additive manufacturing process while reducing the physical and financial constraints of multi-laser systems.
Implementation Method 1
a plurality of optical fibres for delivering a plurality of laser beams
Implementation Method 2
a fibre termination optic aligned to direct the laser beams from output ends of the plurality of optical fibres to the laser beams positioning optic
Implementation Method 3
a contoured termination optic to align and focus the beams efficiently
Implementation Method 4
the laser beams positioning optic movable relative to the fibre termination optic to scan the laser beams across a working surface
Implementation Method 5
The laser beam melts the powder to form a solidified layer
Implementation Method 6
The laser beam melts the powder
Data Source
AI summary
A laser beam scanner including a laser beams positioning optic, a plurality of optical fibres for delivering a plurality of laser beams and a fibre termination optic aligned to direct the laser beams from output ends of the plurality of optical fibres to the laser beams positioning optic. The laser beams positioning optic is movable relative to the fibre termination optic to scan the laser beams across a working surface.