Laser Beam Profiling With Retroreflectors During Powder Bed Scanning
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Solution Overview
Problem
Current methods for determining the beam profile of a laser beam in a processing machine are time-consuming and require significant setup and measurement time, as they typically involve external measuring devices that cannot be used during operation due to space constraints and accessibility issues within the processing chamber.
Innovation Solution
Incorporating a retroreflector in the processing field, which reflects a significant portion of the laser radiation back to the scanner device, allowing for the determination of the beam profile during operation by scanning the retroreflector with the laser beam, thereby increasing detection precision and reducing measurement time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external measuring devices are used to determine the beam profile, then measurement precision can be achieved, but the measurement time increases significantly and the processing machine must be stopped
Solution Approach 1:
The retroreflector enables the laser beam itself to serve as the measurement probe by reflecting a portion of its own radiation back to the detector. This self-service approach eliminates the need for external measuring devices and allows continuous measurement during operation, resolving the contradiction between measurement precision and time loss.
Solution Approach 2:
The retroreflector acts as an intermediary element that couples the laser beam with the detector system. It reflects a controlled portion of the laser radiation back to the scanner device where the detector is located, enabling indirect measurement without requiring external devices or stopping the processing machine.
2Measurement precision
If external measuring devices are introduced into the processing chamber, then beam profile can be measured, but the device complexity and installation space requirements increase
Solution Approach 1:
The laser beam serves its dual function as both the processing tool and the measurement probe. By using the laser beam's own radiation reflected by the retroreflector, the system eliminates complex external measuring devices, reducing overall device complexity while maintaining measurement capability.
Solution Approach 2:
The retroreflector serves multiple functions: it acts as a beam profile measurement target, a radiation source for the detector, and a non-intrusive element that can be integrated into the existing processing chamber without adding significant complexity. This multi-functionality resolves the contradiction between measurement capability and device complexity.
3Measurement precision
If the processing machine is stopped for measurement, then accurate beam profile determination is possible, but productivity decreases
Solution Approach 1:
The measurement process continues uninterrupted during normal processing operations. The retroreflector enables continuous beam profile monitoring without stopping the laser processing or powder bed preparation, maintaining the continuity of useful action and eliminating productivity loss associated with measurement interruptions.
Solution Approach 2:
The system performs self-diagnosis by using the laser beam's own radiation reflected from the retroreflector. This self-service measurement capability allows the processing machine to monitor its beam profile continuously without external intervention or production stoppage, resolving the contradiction between measurement accuracy and productivity.
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
Enables quick and precise determination of the beam profile, allowing for stable and reproducible machining processes without interrupting the production of three-dimensional components, as the beam profile can be determined within minutes or seconds, improving operational efficiency and reducing setup time.
Implementation Method 1
arranging at least one retroreflector (19) in the processing field (13) of the scanner device (11)
Implementation Method 2
detecting laser radiation (20) which is emitted when scanning over the retroreflector (19) is reflected back into the scanner device (11)
Data Source
Figure 1
Figure 2a~3
AI summary
The invention relates to a method for determining a beam profile of a laser beam (6), which is positioned by means of a scanner device (11) in a processing field (13), comprising: arranging at least one retroreflector (19) in the processing field (13) of the scanner device (11), which area is preferably formed in a processing chamber (15) for irradiating powder layers (3), detecting laser radiation (20) which, during scanning travel over the retroreflector (19) with the laser beam (6), is reflected back into the scanner device (11), and determining the beam profile of the laser beam (6) by using the laser radiation (20) detected during the scanning travel over the retroreflector (19). The invention further relates to an associated processing machine (1) for producing three-dimensional components (2) by means of the irradiation of powder layers (3).