Hybrid Laser and Additive Manufacturing for Micro-Feature Edge Refinement
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Solution Overview
Problem
Laser micromachining techniques face limitations in achieving precision and geometry due to diffraction limits, beam uniformity, stochastic material interactions, and irregularities in substrate processing, leading to lengthy production times for micro-scale features like pinholes and apertures.
Innovation Solution
Combining additive manufacturing (AM) with laser machining to refine the edges and surfaces of features, where a coarse void is initially created by laser machining and then refined by AM, allowing for rapid production of precision features with improved edge roughness and geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additive manufacturing is used alone to create precision micro features, then manufacturing precision is improved, but production time increases significantly
Solution Approach 1:
The manufacturing process is divided into two distinct stages: laser machining for rapid bulk material removal to create coarse features, followed by additive manufacturing for precision refinement of edges and surfaces. This segmentation allows each process to optimize for its strength while avoiding its weaknesses.
Solution Approach 2:
Laser machining performs preliminary material removal to create a near-net-shape coarse feature before additive manufacturing refines the precision surfaces. This preliminary action reduces the volume of material that requires time-consuming additive deposition.
2Productivity
If laser machining is used to create micro features, then production speed is improved, but manufacturing precision deteriorates due to diffraction limits and stochastic material interactions
Solution Approach 1:
Additive manufacturing acts as an intermediary refinement process that follows laser machining. It corrects the precision deficiencies of laser machining by depositing material layer-by-layer to create smooth, precise edges and surfaces on the previously rough laser-machined features.
3Productivity
If additive manufacturing deposition volume is reduced, then production time is decreased, but the ability to correct laser machining irregularities is compromised
Solution Approach 1:
Additive manufacturing is applied selectively only to the surface regions requiring precision refinement, rather than building entire features. This localized application minimizes deposition volume and production time while still achieving the necessary geometric precision on critical surfaces.
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 method enables the rapid creation of precision features with submicron resolution and improved edge quality, overcoming the limitations of laser machining by minimizing the time and material required for AM deposition, while addressing irregularities and depth-tapered issues in feature formation.
Implementation Method 1
Laser micromachining can be used to create optical apertures such as pinholes, slits and other patterns. Additionally, lasers drilling can be used to create flow orifices for gas flow and microfluidic applications.
Implementation Method 2
the stochastic nature of melting and ablating the substrate material
Implementation Method 3
the stochastic nature of melting and ablating the substrate material
Implementation Method 4
use of AM to refine the edge or three-dimensional surface of the void through precision deposition of material around the void
Data Source
AI summary
The present disclosure addresses methods to refine the geometry of micro features manufactured in various substrates. Such refinement includes improvement in edge roughness and roughness of aperture channel walls. The methods include deposition of material onto feature edges and surfaces as well as placement of micro fabricated inserts into coarse features. Foremost among the candidate technologies that can be employed for these purposes are two photon polymerization-based 3D nano printing and atomic force microscope nanopipette-based electroplating.