Laser Beam Splitting for Additive Manufacturing Surface Quality
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Solution Overview
Problem
Laser powder melting technology in additive manufacturing is hindered by long process times and rough surface finishes, along with thermal deformation due to thermal stress.
Innovation Solution
A laser device comprising a spectroscope unit and lens assembly that splits and focuses the laser beam into separate beams, reducing surface roughness and process time by controlling the spot size and divergence, and adjusting the beam's direction and spacing for improved processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser powder melting technology is used for additive manufacturing, then complex shape workpieces can be manufactured quickly and accurately, but the process time is long and the surface is rough
Solution Approach 1:
The patent divides a single laser beam into multiple separate beams using a spectroscope unit. This segmentation allows simultaneous processing of multiple areas on the workpiece, reducing overall process time while maintaining or improving surface quality through parallel manufacturing operations
Solution Approach 2:
The patent introduces temporal parallelism by processing multiple spatial locations simultaneously with multiple beams. This dimensional change from sequential single-beam processing to parallel multi-beam processing reduces process time while the coordinated control maintains surface quality standards
2Ease of manufacture
If laser powder melting technology is used for additive manufacturing, then traditional molds and tools are eliminated, but thermal deformation occurs due to thermal stress
Solution Approach 1:
By segmenting the laser beam into multiple beams, the total thermal energy is distributed across multiple processing zones. This reduces concentrated thermal stress in any single area, minimizing thermal deformation while maintaining the ability to manufacture complex freeform structures
Solution Approach 2:
The patent enables different processing parameters to be applied to different regions simultaneously through multiple beams. This allows optimization of local processing conditions to minimize thermal stress and deformation in critical areas while maintaining manufacturing flexibility for complex geometries
3Productivity
If a single laser beam is used for processing, then the device structure is simple, but the process time is long
Solution Approach 1:
The spectroscope unit segments the single laser beam into multiple beams using optical elements. This allows parallel processing that increases productivity while the optical segmentation approach maintains relatively manageable device complexity compared to using multiple independent laser sources
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
The solution significantly reduces surface roughness and process time, optimizing speed and accuracy in additive manufacturing by enabling precise control over the laser beam's focus and scanning strategy.
Implementation Method 1
the spectroscope unit is configured to receive the laser beam and split the laser beam into separate beams
Implementation Method 2
the lens assembly unit is configured to receive the separate beams and reflect the separate beams to a working platform
Data Source
AI summary
A laser device for additive manufacturing and an operation method thereof are provided. The laser device has a laser generation unit, a spectroscopic unit, a control unit, and a lens assembly unit. A laser beam is split into two or more beams by disposing the spectroscopic unit and the lens assembly unit. Thus, a roughness of a process surface and a process time can be reduced.