Laser Array Control With Encoder-Triggered Multi-Laser Synchronization
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Solution Overview
Problem
Conventional powder bed fusion systems are limited by the power per unit area they can deliver while maintaining high part quality, and existing multi-laser systems face challenges in controlling a large number of lasers due to hardware and computational complexity, misalignment issues, and synchronization difficulties.
Innovation Solution
A scalable laser control system that uses a fixed laser array with position-based feedback and a controller architecture to synchronize the operation of a large number of independent lasers, reducing control complexity by using a single high-frequency encoder signal split into lower frequency trigger signals and employing high-speed field programmable gate arrays (FPGAs) for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large number of independent lasers are used to increase power delivery, then the power per unit area delivered to the build surface is improved, but the hardware and computational complexity of controlling the lasers increases
Solution Approach 1:
Multiple independent laser sources are combined into a unified array system that shares common control infrastructure. The lasers are controlled in groups or bundles rather than individually, merging control functions to reduce overall system complexity while maintaining high power delivery capability.
Solution Approach 2:
A single controller is designed to perform multiple functions: it controls positioning, synchronizes multiple laser sources, manages timing sequences, and coordinates with the build surface. This universal controller eliminates the need for separate dedicated control systems for each laser, reducing hardware complexity.
2Power
If a large number of lasers are synchronized using traditional control methods, then the power delivery capability is improved, but the synchronization precision and timing accuracy deteriorate due to computational complexity
Solution Approach 1:
The laser array operates using periodic triggering sequences where lasers are activated in synchronized cycles. A master clock or timing signal generates periodic triggers that coordinate laser firing across the array, ensuring precise synchronization without requiring complex real-time computational coordination for each individual laser event.
Solution Approach 2:
Laser positions and trigger timing are pre-calculated and stored in lookup tables or configuration memory before the additive manufacturing process begins. The controller simply retrieves pre-determined timing information rather than computing it in real-time, maintaining synchronization precision while reducing computational complexity during operation.
3Quantity of substance
If the spacing between the final optical component and build surface is increased to accommodate multiple lasers, then the number of lasers that can be deployed is improved, but the laser beam divergence and spot size uniformity worsen
Solution Approach 1:
The optical system is designed with local optimization where each laser source in the array has its own optimized optical path and focusing arrangement. This allows each laser to maintain proper beam characteristics and spot size uniformity at the build surface regardless of the overall array size or distance from the build surface, enabling deployment of many lasers without sacrificing precision.
Data Source
AI summary
Laser control systems and related methods for controlling arrays of lasers are disclosed. A laser control system may include a first controller configured to generate a trigger signal based on a position of a laser array, and a second controller configured to send a firing signal to one or more lasers of the laser array upon receiving the trigger signal. The one or more lasers may be selected based on a desired pattern of laser energy to be formed at a particular position of the laser array.