Laser Emitter Array Assembly for Fast, High-Resolution 3D Printing
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Solution Overview
Problem
Current additive manufacturing systems face limitations in achieving fast build rates and high resolutions while managing heat dissipation and maintaining precise control over laser emitters in optical-based 3D printing processes.
Innovation Solution
The system incorporates a laser assembly with multiple arrays of laser emitters arranged in oblique angles, a heat sink assembly for efficient heat dissipation, and a controller to independently control the timing and duration of energy emission, allowing for voxel-by-voxel crosslinking of photocurable resin and enabling high-resolution, fast printing with improved heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple arrays of laser emitters are used to increase printing speed and resolution, then productivity and manufacturing precision are improved, but heat generation increases and device complexity increases
Solution Approach 1:
The laser assembly is divided into multiple arrays of laser emitters (e.g., 5 arrays with 5 lasers each) that can be independently controlled. This segmentation allows the system to target specific voxels selectively, concentrating energy only where needed rather than heating large areas, thus improving build rate while managing heat generation more effectively.
Solution Approach 2:
The system employs selective laser sintering where only the specific voxels requiring material fusion receive laser energy. The controller assembly independently controls the timing and duration of energy emission from each laser emitter, ensuring that heat is generated only in the local regions where material bonding is required, rather than uniformly across the entire build platform.
2Manufacturing precision
If multiple arrays of laser emitters are used to increase printing speed and resolution, then productivity and manufacturing precision are improved, but device complexity increases
Solution Approach 1:
Multiple arrays of laser emitters are integrated into a single movable laser assembly that travels along the x-axis. The controller assembly consolidates control of all laser emitters and coordinates their operation with the motion system, merging the control functions to manage complexity while maintaining the precision benefits of multiple lasers.
Solution Approach 2:
The laser assembly serves multiple functions: it provides high-resolution voxel-by-voxel printing through multiple laser arrays, enables fast build rates through parallel processing capability, and maintains maneuverability by being mounted on a movable gantry system. The controller assembly handles both laser emission control and coordination with platform motion.
3Productivity
If laser emitters operate at high power for fast printing, then productivity is improved, but lifespan of laser emitters decreases
Solution Approach 1:
The controller assembly independently controls the timing and duration of energy emission from each laser emitter, enabling pulsed or periodic operation rather than continuous high-power operation. This allows the system to accumulate printing throughput over multiple passes while reducing thermal stress and extending laser emitter lifespan.
Solution Approach 2:
The system uses multiple laser arrays to deliver the required total energy for material fusion, but distributes this energy across multiple emitters rather than overloading a single laser. Each laser emitter operates at moderate power levels with controlled duty cycles, achieving the necessary total energy deposition for fast printing while preventing excessive heat generation that would reduce laser lifespan.
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 enables high-resolution, fast 3D printing with efficient heat dissipation, maintaining precise control over the printing process and extending the lifespan of laser emitters, while allowing for large build envelopes and varied material properties.
Implementation Method 1
at least a portion of a heat sink assembly that is configured to draw heat away from the base block
Implementation Method 2
independent control of at least timing and duration of energy emitted from each laser emitter... allowing for voxel-by-voxel crosslinking of photocurable resin
Data Source
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AI summary
A laser assembly (12) for use with an additive manufacturing system (10), which includes a base block (50) configured to be moved along a scan direction axis in the additive manufacturing system, a plurality of laser emitters (30) preferably arranged in an array of at least two rows of two or more laser emitters. At least a portion of a heat sink assembly (74) is configured to draw heat away from the base block and/or the laser emitters. The assembly includes a controller assembly (26) a controller assembly configured to control a movement of the base block along the first axis and to independently control at least timing and duration of energy emitted from each laser emitter of the plurality of laser emitters as the base block moves along the first axis.