Laser Beam Splitting for Additive Manufacturing Power Consistency
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Solution Overview
Problem
Additive manufacturing processes, such as selective laser sintering and stereolithography, face limitations due to laser beam divergence, leading to reduced build quality and capacity, especially when using single laser sources, which result in power variations and increased calibration demands.
Innovation Solution
A laser assembly and method utilizing a combination of fixed and oscillating mirrors to split and refract laser beams, ensuring consistent power distribution across a material bed by reflecting a fixed percentage of the laser beam power at each mirror, reducing the need for calibration and power variations between different laser sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional laser beam sources are added to reduce beam travel distance, then build quality improves, but power variations between laser beams occur
Solution Approach 1:
The patent segments a single laser beam into multiple parallel beams using beam splitting optics. This allows multiple beams to simultaneously process different regions of the powder bed, reducing travel distance and improving build quality while maintaining consistent power distribution across all beams through controlled splitting ratios
Solution Approach 2:
The patent introduces beam combining and splitting optics as intermediary elements between the single laser source and the powder bed. These intermediaries distribute the laser energy uniformly across multiple beams, eliminating power variations that would otherwise occur when using multiple independent laser sources
2Ease of operation
If single laser beam source is used, then calibration requirements are reduced, but processing speed decreases and build capacity is limited
Solution Approach 1:
The single laser beam is segmented into multiple parallel beams that can simultaneously process multiple regions of the build area. This increases processing speed and build capacity while maintaining the simplicity of a single laser source, thereby reducing calibration requirements
Solution Approach 2:
The patent combines the functionality of multiple laser sources into a single laser beam through optical splitting and combining. This merging approach achieves the productivity benefits of multiple beams while retaining the operational simplicity and reduced calibration needs of a single source
3Area of stationary object
If laser beam travels greater distance across the bed, then build capacity increases, but beam divergence reduces quality
Solution Approach 1:
The patent creates multiple parallel laser beams that can simultaneously cover different regions of the powder bed. This segmentation allows the system to increase build capacity by expanding the processed area while maintaining high quality through reduced beam travel distance for each individual beam
Solution Approach 2:
The patent transitions from single-beam sequential processing to multi-beam parallel processing by adding spatial distribution in the lateral dimension. This allows simultaneous processing across the build area, increasing capacity without compromising quality through excessive beam travel
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 the quality and capacity of additive manufacturing by maintaining consistent energy delivery to the material bed, reducing power variations, and minimizing calibration requirements, thereby improving the overall production quality and efficiency.
Implementation Method 1
a first partial reflecting fixed mirror positioned aligned with the first direction which reflects a first portion of the first laser beam in a second direction
Implementation Method 2
a first oscillating mirror positioned aligned with the second direction of the first portion of the first laser beam wherein the first portion of the first laser beam is refracted by the first oscillating mirror in a third direction
Data Source
Figure 1
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AI summary
A laser assembly (10) for additive manufacturing which includes a first laser beam (12) aligned in a first direction (D1) and a first partial reflecting fixed mirror (16) positioned aligned with the first direction (D1) which reflects a first portion (18) of the first laser beam (12) in a second direction (D2) and an exponentially reduced remaining second portion (20) of the first laser beam (12) passes through the first partial reflecting fixed mirror (16) in the first direction (D1). The laser beam assembly (10) further includes a first oscillating mirror (22) positioned aligned with the second direction (D2) of the first portion (18) of the first laser beam (12) wherein the first portion (18) of the first laser beam (12) is refracted by the first oscillating mirror (22) in a third direction (D3).