Additive Manufacturing Laser Frame with Cellular Cooling
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Solution Overview
Problem
Conventional laser systems are sensitive to mechanical disturbances and thermal management issues, limiting their design to heavy, bulky constructions with restricted geometries and inadequate cooling, which affects beam quality and power output.
Innovation Solution
A laser frame manufactured using additive manufacturing techniques, incorporating flexure structures for adjustable optical components and passive or active cooling cellular structures with non-uniform density, enabling a compact, lightweight, and customizable design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If heavy metals are used for construction to ensure mechanical stability, then stability is improved, but weight increases unnecessarily
Solution Approach 1:
The laser system is divided into modular components (laser source module, optical module, power supply module, cooling module) that can be independently designed and assembled. This segmentation allows each module to be optimized for its specific function while reducing overall system weight compared to a monolithic heavy metal construction.
Solution Approach 2:
Different materials and structural densities are used in different parts of the system based on local requirements. Critical components requiring high stability use denser materials, while non-critical areas use lighter materials. The mounting structure incorporates localized reinforcement only where mechanical stability is essential.
2Ease of manufacture
If conventional CNC machining is used to manufacture parts, then manufacturing is straightforward, but geometry types are restricted
Solution Approach 1:
The design transitions from 2.5D CNC-machined surfaces to true 3D complex geometries enabled by additive manufacturing. Internal cooling channels, lattice structures, and organic shapes are created in three dimensions that would be impossible or extremely costly to produce with conventional machining methods.
Solution Approach 2:
The manufacturing process parameters are changed from subtractive (CNC machining) to additive (3D printing) methods. This fundamental parameter change enables the creation of complex internal structures, variable thickness walls, and optimized thermal pathways that cannot be achieved through traditional machining.
3Temperature
If heat accumulates in the laser system, then thermal management becomes insufficient, but thermal expansion causes misalignment and stress fractures
Solution Approach 1:
A liquid cooling system with coolant channels is integrated into the laser housing and heat-generating components. The coolant (typically water or water-glycol mixture) circulates through these channels to actively remove heat from the laser source, optical mounts, and power supply, preventing thermal accumulation and maintaining dimensional stability.
Solution Approach 2:
The design accounts for thermal expansion by using materials with matched thermal expansion coefficients for components in thermal contact. Expansion compensation mechanisms are incorporated in the mounting structure to maintain optical alignment despite temperature variations during operation.
4Ease of manufacture
If off-the-shelf cage and rail systems are used, then assembly is simplified, but customization for special needs is limited
Solution Approach 1:
The laser system is designed as a modular platform where core components (housing, mounting structure, cooling system) serve multiple functions. The standardized interface design allows different optical modules and accessories to be integrated into the same platform, providing universality while maintaining customization capability through module selection and configuration.
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 provides a stable, compact, and customizable laser system with improved thermal management and reduced weight, enhancing beam quality and power output while allowing for diverse design implementations without additional manufacturing costs.
Implementation Method 1
A laser frame manufactured using additive manufacturing techniques, incorporating flexure structures for adjustable optical components and passive or active cooling cellular structures
Implementation Method 2
passive cooling cellular structure for supporting and cooling the optical component
Implementation Method 3
effective cooling structures are required to dissipate that heat
Implementation Method 4
a first flexure structure for adjustably holding a first one of the optical components
Data Source
AI summary
A laser frame for holding a plurality of optical components includes a first flexure structure for adjustably holding a first one of the optical components, and a first cellular structure for supporting and cooling a second one of the optical components. The first flexure structure and the first cellular structure are each a unitary structure formed by additive manufacturing. Also, a laser frame for holding an optical component includes a passive cooling cellular structure for supporting and cooling the optical component. The passive cooling cellular structure has a non-uniform density, and the laser frame is a unitary structure formed by additive manufacturing.