Isolated Laser Source for Additive Manufacturing Gantry

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Solution Overview

Problem

Additive manufacturing apparatuses face challenges in maintaining pointing accuracy due to high mechanical loading on positioning systems, which are subjected to heavy scanner assemblies, leading to difficulties in precision and increased complexity with moving components.

Innovation Solution

The laser beam source assembly is isolated from the positioning system, delivering a collimated laser beam through free space to a receiver assembly, which steers and focuses the beam onto the print head, reducing mechanical loading and eliminating the need for moving fiber lasers, thus minimizing fiber fatigue and simplifying maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If heavy scanner assemblies are mounted on positioning systems, then laser beam delivery capability is achieved, but mechanical loading increases and pointing accuracy deteriorates

Engineering Contradiction:

Improvepointing accuracyVSAvoidmechanical loading

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The patent extracts the heavy laser source and scanner assembly from the moving positioning system (gantry), isolating them in a stationary housing. Only lightweight optical components (mirrors, beam delivery system) remain on the gantry, dramatically reducing mechanical loading and improving pointing accuracy while maintaining laser delivery capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical laser source mounting system with an optical beam delivery system. Instead of mechanically moving the laser source with the gantry, stationary lasers project beams through free space to stationary receivers on the gantry, substituting mechanical coupling with optical coupling and eliminating associated mechanical loading and fiber fatigue issues.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If complex scanner assemblies with moving components are used, then laser beam steering capability is achieved, but device complexity increases and maintenance difficulty increases

Engineering Contradiction:

Improvelaser beam steering capabilityVSAvoidscanner assembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent uses optical copying principles where stationary laser sources project beams through free space to receivers on the gantry. The beam path and steering information are effectively 'copied' optically rather than physically moving the laser source, simplifying the moving components while maintaining steering capability.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent extracts the complex scanner assembly from the moving gantry and replaces it with simpler optical components (mirrors, beam delivery system). The laser source and main scanner housing remain stationary, removing complexity from the moving portion while retaining beam steering functionality through the optical path.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If fiber lasers are mounted on moving positioning systems, then portable laser delivery is achieved, but fiber fatigue increases and maintenance requirements increase

Engineering Contradiction:

Improvelaser delivery efficiencyVSAvoidfiber fatigue resistance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces mechanical fiber optic coupling with free-space optical coupling. Stationary lasers project beams through air/vacuum to receivers on the gantry, eliminating the need for flexible fiber optics in the moving path. This substitution removes fiber fatigue issues entirely while maintaining efficient laser delivery to the build area.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 configuration enhances precision, reduces mechanical stress on the positioning system, simplifies maintenance, and minimizes contamination risks, while maintaining accurate laser beam positioning and focusing.

Implementation Method 1

The laser beam source assembly is isolated from the positioning system and delivers a collimated laser beam through free space to a receiver assembly

Methodology Applied

Scientific EffectLight propagation: Light

Implementation Method 2

the receiver assembly steers and focuses the beam onto the print head

Methodology Applied

Scientific EffectOptical reflection: Reflection

Implementation Method 3

the receiver assembly steers and focuses the beam onto the print head

Methodology Applied

Scientific EffectOptical focusing: Focusing

Data Source

PatentUS20240375184A1Additive manufacturing apparatuses including gantry for directing collimated laser beam

Publication Date: 2024.11.14 GENERAL ELECTRIC CO

AI summary

Disclosed herein are additive manufacturing apparatuses which include a print head supported by a positioning system, the print head including one or more delivery optics contained within the print head; a laser beam source assembly isolated from the positioning system, the laser beam source assembly configured to generate at least one collimated laser beam; and a laser beam receiver assembly isolated from the laser beam source assembly, the laser beam receiver assembly configured to receive the at least one collimated laser beam and direct the at least one collimated laser beam to the one or more delivery optics of the print head.