Automated Laser Material Dispensing System
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Solution Overview
Problem
Conventional methods for applying materials to workpieces in laser-based processing systems are labor-intensive and inefficient, requiring manual application or multiple masking and spraying steps, which reduce throughput and increase costs.
Innovation Solution
A laser-based material processing system that integrates a positioning assembly, a laser beam director, and a dispensing unit, allowing for automated application of materials onto workpieces, with the ability to coordinate the laser beam and dispensing unit's movement relative to the workpiece, enabling simultaneous or sequential material deposition during or after irradiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual application of material onto the workpiece is used, then the material can be applied with some precision, but the process is very labor-intensive and significantly reduces throughput
Solution Approach 1:
The patent replaces manual mechanical application of materials with an automated dispensing system controlled by a computer. The dispensing unit is positioned by a positioning assembly that can precisely move it along the workpiece, eliminating manual labor while maintaining controlled material application. This automation directly addresses the contradiction by improving throughput without sacrificing precision.
Solution Approach 2:
The system enables self-service automation where the dispensing unit automatically applies materials based on programmed instructions from the controller. The positioning assembly automatically moves the dispensing unit to the correct locations, and the system can operate autonomously without continuous human intervention, thereby increasing productivity while reducing labor intensity.
2Productivity
If masking and spraying steps are used to apply material, then material can be deposited onto the workpiece, but the process is labor-intensive and requires additional process steps that reduce throughput
Solution Approach 1:
The patent extracts and eliminates the masking step from the conventional process. Instead of applying masks and then spraying, the dispensing unit directly deposits material only at the desired locations on the workpiece. This removal of the masking step reduces process complexity and eliminates the associated labor and time requirements, thereby improving throughput.
Solution Approach 2:
The system performs preliminary positioning of the dispensing unit to exact locations before material deposition. The positioning assembly pre-positions the dispensing unit based on programmed coordinates, eliminating the need for masking to define application areas. This preliminary precise positioning simplifies the overall process by removing masking and spraying steps while maintaining controlled material application.
3Manufacturing precision
If masks are formed and used for material application, then precise material deposition can be achieved, but forming the masks is relatively expensive and requires a significant amount of time
Solution Approach 1:
The patent replaces the mechanical masking process with a digitally controlled positioning system. The controller receives digital instructions specifying exact deposition locations and moves the dispensing unit accordingly, eliminating the need for physical masks. This substitution maintains precise material deposition while eliminating the time-consuming mask formation process entirely.
Solution Approach 2:
The system uses digital copies or representations of the workpiece geometry and material deposition patterns stored in the controller. Instead of creating physical masks, the controller uses digital models to guide the positioning assembly and dispensing unit to the correct locations, achieving precise material deposition without the time and cost of physical mask fabrication.
4Productivity
If manual material application is used, then flexibility in material selection can be maintained, but the process is very labor-intensive and reduces processing efficiency
Solution Approach 1:
The system achieves self-service automation where the positioning assembly and dispensing unit operate autonomously based on programmed instructions. The controller automatically controls the positioning, movement, and material deposition without continuous manual intervention. This high level of automation dramatically improves processing efficiency while the system can still handle various materials by changing the material supply source according to program instructions.
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 system significantly improves throughput and reduces processing time and costs by enabling automated, precise, and efficient material application directly on the workpiece, eliminating the need for manual handling and minimizing misalignment errors.
Implementation Method 1
irradiating a portion of a workpiece with a laser beam
Implementation Method 2
laser energy can fuse the applied material to the workpiece
Data Source
AI summary
Laser-based material processing systems and methods for using such systems are disclosed herein. In one embodiment, for example, a laser-based material processing system includes a workpiece support, a positioning assembly over at least a portion of the workpiece support, and a laser. The system includes a laser beam director carried by the positioning assembly to direct a beam generated by the laser toward the workpiece support. The system also includes a dispensing unit carried by the positioning assembly to discharge a material toward the workpiece support. The system further includes a controller operably coupled to the positioning assembly, the laser beam director, and the dispensing unit. The controller can be configured to move the laser beam director and the dispensing unit relative to the workpiece support such that (a) the beam is directed toward a first portion of the workpiece support, and (b) the dispensing unit discharges material toward the first portion of the workpiece support.