Fiber-Fed Laser Optic Head for Simpler Powder Bed Additive Manufacturing
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Solution Overview
Problem
Existing laser additive manufacturing systems are complex and expensive due to the use of moving optical parts like deflection mirrors, lenses, and coils to change the direction of the laser beam, which complicates the system and increases costs.
Innovation Solution
A laser additive manufacturing system that uses a flying laser optic head sliding along a rail mechanism in the X-direction, coupled with a powder feeder moving in the Y-direction and a build plate moving in the Z-direction, to focus the laser beam on different focal spots without the need for complex beam deflection systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If moving optical parts (deflection mirrors, lenses, coils) are used to change the direction of the laser beam, then the laser beam can be directed to different focal spots, but the system becomes complex and expensive
Solution Approach 1:
The patent replaces the traditional mechanical/optical deflection system (mirrors, lenses, coils) with a fiber optic delivery system. The laser beam is transmitted through a flexible fiber optic cable to a stationary or movable optic head that contains only a simple focusing lens, eliminating the need for complex beam deflection mechanisms while maintaining the ability to direct the beam to different focal spots.
Solution Approach 2:
The patent extracts the beam deflection function from the optical system by separating the laser source from the focal point using a fiber optic cable. This allows the laser source to remain stationary while the fiber optic delivers the beam to the workpiece, removing the need for moving mirrors and complex optical components at the focal end.
2Adaptability or versatility
If moving optical parts are used to change the direction of the laser beam, then different focal spots can be reached, but the system cost increases
Solution Approach 1:
The patent replaces expensive moving optical components (deflection mirrors, precision lenses, electromagnetic coils) with a cost-effective fiber optic delivery system. The fiber optic cable and simple focusing lens assembly are significantly cheaper than the traditional deflection system while achieving the same functional result of directing the laser beam to various focal spots.
Solution Approach 2:
The patent uses a fiber optic cable that can be easily replaced or repositioned compared to the expensive, precision-aligned optical components in traditional systems. The fiber optic head with its simple lens assembly is a cost-effective alternative to complex deflection mechanisms, reducing overall system cost while maintaining versatility.
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 simplifies the system architecture, reduces costs, and enhances manufacturing efficiency by allowing the laser beam to be focused on different spots through the movement of the optic head, rather than relying on complex optical deflection systems.
Implementation Method 1
a fiber optic coupled to the laser to transmit the laser beam to a laser optic head
Implementation Method 2
The laser beam generated by the laser is focused using the laser optic head onto a small region of the powder bed
Implementation Method 3
The laser beam generated by the laser is focused using the laser optic head onto a small region of the powder bed where the powdered material is positioned producing small volumes of melt pools
Data Source
AI summary
Examples of a laser additive manufacturing system are described. The system comprises a laser configured to generate a laser beam, a fiber optic coupled to the laser to transmit the laser beam to a laser optic head that is coupled to the fiber optic and comprises a focus lens to focus the light beam. The laser optic head is configured to slide along a sliding mechanism in X-direction. A powder feeder is used to continuously move in Y-direction and dispense an uniform layer of powdered material onto a powder bad that is positioned on a build plate of the building chamber. The build plate is configured to move in Z-direction. The light beam generated by the laser is focused using the laser optic head onto a small region of the powder bed where the powdered material is positioned producing small volumes of melt pools that are then cooled and a new layer of powdered material is dispensed over it.