Galvano Scanner Layout for Uniform 3D Laser Sintering
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Solution Overview
Problem
Existing three-dimensional shaping methods using multiple galvano scanners for laser beam irradiation suffer from inefficient scanning and sintering due to unclear mirror placement and unspecified rotation axes, leading to non-uniform sintered surfaces and excess energy consumption.
Innovation Solution
A method and apparatus employing multiple galvano scanners with dynamically focused laser beams, where first and second mirrors oscillate independently in perpendicular directions, allowing for free adjustment of their ranges to selectively sinter regions, with one mirror positioned outer and the other inner relative to the center, ensuring precise two-dimensional scanning and irradiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If laser beams are scanned over the entire focal plane region, then the scanning coverage is maximized, but excess scanning and irradiation occur in regions that do not require sintering, reducing efficiency
Solution Approach 1:
The patent applies local quality by making the oscillation ranges of the first and second mirrors adjustable and independent, allowing the laser beam to be precisely directed only to the specific regions on the focal plane that require sintering. This enables different regions to receive different treatments (sintering or no irradiation), eliminating excess scanning in non-sintering regions while maintaining complete scanning coverage where needed.
2Adaptability or versatility
If the mirror placement and rotation axes are not clearly specified, then the system design is flexible, but uniform scanning and sintered surfaces cannot be achieved
Solution Approach 1:
The patent applies dynamics by making the oscillation ranges of the first and second mirrors independently adjustable. This dynamic control system allows the mirrors to adapt their oscillation amplitudes to achieve precise two-dimensional scanning patterns, ensuring uniform laser beam irradiation and consistent sintered surfaces while maintaining design flexibility for different application requirements.
3Area of stationary object
If multiple galvano scanners are used for efficient scanning, then the space required is reduced, but the system complexity increases due to multiple mirrors and oscillation controls
Solution Approach 1:
The patent applies universality by designing the first and second mirrors with independent and adjustable oscillation ranges, allowing each mirror to perform multiple functions: the first mirror provides primary oscillation for one dimension of scanning, while the second mirror provides orthogonal oscillation for the other dimension. This multi-functional design enables compact space utilization while the coordinated control of both mirrors achieves the complex two-dimensional scanning pattern required for efficient three-dimensional shaping.
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 efficient, uniform, and compact three-dimensional shaping with reduced energy consumption, allowing for independent sintered surface formation and avoiding excess scanning, while maintaining system reliability by allowing other scanners to compensate for malfunctions.
Implementation Method 1
a laser beam that has been transmitted through a dynamic focus lens with an adjustable focal length is used for scanning on the sintered surface
Implementation Method 2
sintering a laminated powder layer by irradiation of laser beams
Implementation Method 3
a laser beam that has been transmitted through a dynamic focus lens with an adjustable focal length
Implementation Method 4
a plurality of galvano scanners that scan laser beams along two-dimensional directions
Implementation Method 5
first mirrors that oscillate on rotation axes in directions perpendicular to the transmission direction and second mirrors that oscillate on rotation axes in horizontal directions
Data Source
Figure 1
Figure 2(a)~2(c)
Figure 3(a)~3(b)
AI summary
[Problem to be Solved] To provide a construction allowing three-dimensional shaping by efficient and uniform two-dimensional scanning, wherein all of laser beams scanned after being transmitted through a plurality of galvano scanners contribute to formation of sintered surface. [Solution] The three-dimensional shaping method and apparatus employs a plurality of galvano scanners 3 that carry out scanning of laser beams 7 along two-dimensional directions on orthogonal coordinates or cylindrical coordinates by reflection from first mirrors 31 that oscillate on a rotation axes 30 that are perpendicular to transmission directions of the laser beams 7 that have been transmitted through dynamic focus lenses 2, and second mirrors 32 that oscillate on the rotation axes 30 that are perpendicular to the rotation axes 30 of the first mirrors 31 and are in horizontal directions, the aforementioned object being achieved by having oscillation ranges freely adjustable based on control of an oscillation, and having freely selectable regions on a sintered surface 6 at the focal points of the laser beams 7 irradiated in slanted directions with respect to a surface of a table 4, or locations in their vicinity.