Laser Beam Shaping for 3D Energy Distribution in Material Processing
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Solution Overview
Problem
Conventional laser material machining methods with static beam geometries fail to achieve optimal machining results due to limited flexibility in adapting laser power density distribution, restricting process efficiency and quality.
Innovation Solution
A device and method incorporating a laser beam source, beam shaping element, and optical deflection element that allow for continuous emission and dynamic adjustment of the laser beam's focal plane and intensity distribution, enabling three-dimensional beam shaping and movement to achieve desired energy density distributions on the workpiece surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If static beam geometries are used in conventional laser material machining, then the device complexity is reduced, but the adaptability of laser power density distribution is limited
Solution Approach 1:
The patent applies dynamics by replacing static beam geometries with dynamic beam shaping elements that can continuously adjust the laser beam's focal plane position and intensity distribution. The beam shaping element is movable along the optical axis, enabling real-time adaptation of beam parameters to achieve optimal power density distribution for different machining requirements.
Solution Approach 2:
The beam shaping element serves multiple functions: it adjusts the focal plane position, modifies intensity distribution, and controls beam geometry. This multi-functionality allows a single device component to address various machining needs, improving adaptability without proportionally increasing overall device complexity.
2Adaptability or versatility
If dynamic beam shaping methods are used to adapt power density distribution, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The optical system is segmented into distinct functional components: the laser beam source, the movable beam shaping element, the optical deflection element, and the focusing element. This segmentation allows each component to be optimized independently and facilitates flexible configuration to achieve desired beam characteristics without overwhelming complexity.
Solution Approach 2:
The beam shaping element acts as an intermediary between the laser beam source and the workpiece, mediating the transformation of the beam's properties. By positioning this element movably in the optical path, the system achieves dynamic control over beam parameters while maintaining a relatively simple overall structure.
3Manufacturing precision
If the focal plane position is adjusted to achieve three-dimensional energy distribution, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The focal plane position is dynamically adjustable through the movable beam shaping element, enabling precise three-dimensional energy distribution control. The element's position along the optical axis directly controls the focal plane location, providing a simple yet effective mechanism for achieving the desired precision without complex additional components.
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 provides enhanced flexibility and adaptability in laser material machining, enabling optimal machining results by allowing for precise control of energy distribution and interaction time, improving process efficiency and quality in both cutting and welding processes.
Implementation Method 1
The optical deflection element typically has one or two elements that reflect the laser beam, preferably mirrors
Implementation Method 2
a focusing element arranged between the optical deflection element and a workpiece surface to be processed
Implementation Method 3
The beam shaping element is configured to change a position of a focal plane of the laser beam relative to the workpiece surface by a translatory movement and/or is configured to change an intensity distribution or a lateral energy distribution within a beam cross-section
Implementation Method 4
a laser beam source for a continuous emission of a laser beam
Data Source
AI summary
A device and a method for beam shaping and beam movement during laser material processing with a laser beam source (1) for continuously emitting a laser beam (2), a first optical deflection element (3), a second optical deflection element (4), and an optical focusing element (5) arranged between the second optical deflection element (4) and a workpiece surface (7) to be processed. The second optical deflection element (4) is configured to displace a point of incidence of the laser beam (2) on the workpiece surface (7), and the first optical deflection element (3) is configured to alter a position of a focal plane of the laser beam (2) relative to the workpiece surface (7) by means of a translational movement and/or to change an intensity distribution within a beam cross section of the laser beam.