Additive Manufacturing Array of Laser Diodes for Build Speed
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Solution Overview
Problem
Current additive manufacturing systems, particularly in powder bed fusion processes, face challenges in achieving increased build speed and reduced per-part build cost due to limitations in energy beam characteristics.
Innovation Solution
The use of an array of individually controlled laser diodes that direct laser beams to a build platform, allowing for precise control of microstructure formation and material properties through selective emission and manipulation of laser energy, including the use of optical elements to steer and focus the beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single laser beam is used in powder bed fusion, then manufacturing precision is maintained, but productivity is limited
Solution Approach 1:
The single laser beam system is segmented into multiple independent laser beams (e.g., array of 70-100+ laser diodes), allowing simultaneous processing of multiple locations on the powder bed, thereby increasing build speed while maintaining manufacturing precision through individual beam control
Solution Approach 2:
Multiple laser beams are merged into a coordinated system that operates simultaneously on different regions of the build platform, combining their productive capacity while using a shared control architecture and optical delivery system to manage complexity
2Manufacturing precision
If laser beam parameters are optimized for melting, then manufacturing precision improves, but build speed decreases
Solution Approach 1:
Different regions of the build platform receive laser beams with locally optimized parameters - some areas use parameters optimized for rapid melting while others use parameters for precise sintering, allowing simultaneous achievement of high build speed and manufacturing precision across different zones
Solution Approach 2:
The laser beams operate in periodic pulsed sequences with varying duty cycles and timing patterns, allowing thermal management that maintains precision while increasing overall throughput through optimized heating cycles
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 enables faster, more efficient, and accurate formation of three-dimensional objects with improved control over mechanical and surface properties, such as strength, ductility, and roughness, by optimizing heat input and microstructural formation.
Implementation Method 1
an array of laser diodes, each laser diode configured to direct a laser beam toward the build platform
Implementation Method 2
laser beam is directed onto a powder bed to melt and/or sinter sequential layers of powder material
Implementation Method 3
use of optical elements to steer and focus the beams
Data Source
AI summary
A system for additively manufacturing a three-dimensional object is provided. The system includes a build platform, an array of laser diodes, each laser diode of the array of laser diodes configured to direct a laser beam toward the build platform, and a controller communicatively coupled to each laser diode of the array of laser diodes such that control signals are communicated from the controller to each laser diode individually.