In-Fiber Laser Beam Adjuster for Additive Manufacturing
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Solution Overview
Problem
Current fiber-coupled laser systems require complex and costly mechanisms to adjust beam characteristics, often relying on free-space optics that increase complexity, cost, and reduce reliability, while existing additive manufacturing techniques struggle to tailor stress states in 3D objects due to high cooling rates and material variations.
Innovation Solution
The development of an in-fiber apparatus that adjusts optical beam characteristics by perturbing the fiber, allowing for variable beam parameters such as beam diameter, divergence, and intensity distribution without the need for free-space optics, and using these adjusted beams to selectively anneal or harden regions within 3D objects during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If free-space optics or complex mechanisms are used to adjust beam characteristics, then beam parameter adjustability is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple beam adjustment functions (focus, magnification, astigmatism correction) into a single aspheric lens element, eliminating the need for multiple separate optical components and their associated mechanical adjustment mechanisms
Solution Approach 2:
The patent extracts the beam adjustment functionality from complex mechanical systems and consolidates it into a single optical element (aspheric lens), removing unnecessary mechanical complexity while preserving optical functionality
2Adaptability or versatility
If free-space optics are used to vary beam characteristics, then beam parameter flexibility is improved, but reliability decreases due to additional components
Solution Approach 1:
The patent merges multiple optical adjustment functions into a single aspheric lens element, reducing the number of components that could fail and eliminating mechanical adjustment mechanisms that require maintenance
Solution Approach 2:
The aspheric lens provides automatic beam characteristic adjustment through its fixed optical design, eliminating the need for mechanical adjustment mechanisms that require actuation and control systems
3Device complexity
If conventional laser systems with fixed beam characteristics are used, then system simplicity is maintained, but processing optimization for different tasks is compromised
Solution Approach 1:
The aspheric lens enables changing beam parameters (focus position, magnification, astigmatism) by adjusting the lens position relative to the fiber output, allowing optimization for different processing tasks while maintaining system simplicity
4Reliability
If bulk annealing processes are used for stress relief, then stress relief is achieved, but processing time and energy consumption increase
Solution Approach 1:
The patent applies localized annealing to specific regions requiring stress relief rather than heating the entire part, reducing processing time and energy consumption while maintaining effectiveness where needed
Solution Approach 2:
The patent applies partial annealing to only the portions of the part requiring stress relief rather than complete bulk annealing, optimizing the balance between stress relief effectiveness and processing efficiency
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 and cost-effective tailoring of stress states in 3D objects by adjusting laser beam characteristics in real-time, reducing material defects and improving mechanical properties without the need for post-processing treatments.
Implementation Method 1
exposing the layer of particles to a first laser beam having a first set of beam characteristics, thereby heating the layer sufficiently to fuse at least a portion of the particles together
Implementation Method 2
exposing a first region of one of i) the layer of particles or ii) the build layer to a second laser beam having a second set of beam characteristics to provide a first temperature profile for the first region
Implementation Method 3
perturbing an optical beam propagating within a first length of fiber to adjust one or more beam characteristics of the optical beam
Implementation Method 4
coupling the perturbed optical beam into a second length of fiber and maintaining at least a portion of one or more adjusted beam characteristics within a second length of fiber having one or more confinement regions
Data Source
AI summary
A method of making a three-dimensional object. The method comprises: a) positioning a layer of particles over a build plate; b) exposing the layer of particles to a first laser beam having a first set of beam characteristics, thereby heating the layer sufficiently to fuse at least a portion of the particles together to form a build layer; c) exposing a first region of one of i) the layer of particles or ii) the build layer to a second laser beam having a second set of beam characteristics to provide a first temperature profile for the first region; and d) exposing a second region of one of i) the layer of particles or ii) the build layer to a third laser beam having a third set of beam characteristics to provide a second temperature profile for the second region, the second temperature profile being different than the first temperature profile, wherein both the first region and the second region are in the layer of particles or both the first region and the second region are in the build layer.