Fiber-Based Laser Beam Shaping for Additive Manufacturing
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Solution Overview
Problem
Current laser systems for additive manufacturing face challenges in adjusting beam characteristics without relying on free-space optics, leading to increased cost, complexity, and performance degradation, and struggle with steep spatial temperature gradients causing rapid cooling rates and stress in materials.
Innovation Solution
The use of a fiber-based system with adjustable beam characteristics, achieved through a perturbation device that modifies the beam in a first length of fiber, which is then preserved or further altered in a second length of fiber with confinement regions, allowing for variable beam parameters like diameter, divergence, and intensity distribution without the need for free-space optics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If free-space optics or complex add-on mechanisms are used to vary beam characteristics, then beam adjustability is improved, but cost, size, weight, complexity, and reliability are degraded
Solution Approach 1:
The patent replaces mechanical free-space optics systems with an all-fiber solution using a photonic crystal fiber structure. The fiber inherently provides beam characteristic control through its microstructured design, eliminating the need for external mechanical optical components like lenses, mirrors, and beam expanders.
Solution Approach 2:
The patent changes the physical parameters of the fiber itself to achieve beam control. By modifying the photonic crystal fiber's structural parameters (hole patterns, core size, cladding design), different beam characteristics are achieved without external adjustment mechanisms.
2Adaptability or versatility
If free-space optics or complex add-on mechanisms are used to vary beam characteristics, then beam adjustability is improved, but cost is increased
Solution Approach 1:
The patent replaces expensive mechanical free-space optics systems with a more cost-effective all-fiber solution. The photonic crystal fiber structure provides the same beam control functions at lower cost by eliminating multiple optical components and their associated mounting, alignment, and maintenance requirements.
3Adaptability or versatility
If free-space optics or complex add-on mechanisms are used to vary beam characteristics, then beam adjustability is improved, but reliability is degraded
Solution Approach 1:
The patent replaces mechanical free-space optics systems with a more reliable all-fiber solution. Fiber-optic systems are inherently more robust as they eliminate mechanical moving parts, alignment issues, and sensitivity to environmental factors like vibration and temperature changes that plague free-space optical systems.
4Power
If high-power laser beams are used for material melting, then processing power is improved, but steep spatial temperature gradients cause rapid cooling rates and material stress
Solution Approach 1:
The patent applies local quality by using photonic crystal fiber structures to control the spatial distribution of the laser beam. The fiber's microstructured design allows for tailored intensity profiles that can reduce peak power concentrations while maintaining overall processing power, thereby reducing thermal gradients and material stress.
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 approach enables cost-effective, flexible, and reliable adjustment of laser beam characteristics for optimized heat deposition in additive manufacturing, reducing stress and improving material properties by controlling cooling rates and temperature gradients.
Implementation Method 1
a first optical beam source configured to generate a first optical beam; an optical system configured to move the generated first optical beam over a target area
Implementation Method 2
The optical system can be further configured to move the generated second optical beam over the target area so that a path of the second optical beam moving over the target area is dithered about a path of the first optical beam moving over the target area
Implementation Method 3
These lasers include, for example, fiber lasers, disk lasers, diode lasers, diode-pumped solid state lasers, and lamp-pumped solid state lasers
Data Source
AI summary
An apparatus for heat deposition in additive manufacturing may include: a first optical beam source configured to generate a first optical beam; a second optical beam source configured to generate a second optical beam; and/or an optical system. The optical system may be configured to move the generated first optical beam over a target area. The optical system may be further configured to move the generated second optical beam over the target area so that a path of the second optical beam moving over the target area is dithered about a path of the first optical beam moving over the target area.The optical system may be configured to focus the generated first optical beam at a plane of a target area. The optical system may be further configured to focus the generated second optical beam at the plane of the target area.