3D Laser Module Layout for Homogeneous Additive Printing
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Solution Overview
Problem
Existing laser printing systems for 3D additive manufacturing face challenges in reliability and processing speed due to the use of single high-power lasers or arrays, which can result in malfunctions and increased service costs, and struggle with achieving homogeneous energy distribution across the working plane.
Innovation Solution
A laser printing system utilizing multiple semiconductor laser arrays, where at least two laser arrays are imaged to multiple pixels using an optical element, providing diffuse overlapping images to ensure continuous illumination and increased power density without relying on sharp projections, thus enhancing reliability and reducing the impact of individual laser malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single high-power laser is used, then power density is sufficient for processing, but reliability decreases and service costs increase due to malfunctions
Solution Approach 1:
The patent divides a single high-power laser source into multiple lower-power semiconductor laser arrays. Each array contributes a portion of the total required power, and multiple arrays illuminate each pixel area. This segmentation reduces the power burden on individual lasers, improving reliability while maintaining sufficient power density through the combined output of multiple arrays.
2Reliability
If arrays of lasers are used, then reliability improves through redundancy, but manufacturing precision decreases due to difficulty in achieving homogeneous energy distribution
Solution Approach 1:
The patent merges the output of multiple laser arrays by imaging them to overlap on the same pixel area. The optical system combines the light from multiple arrays so that they summate in the working plane, creating a homogeneous energy distribution. This merging approach maintains reliability through redundancy while solving the energy distribution problem through optical superposition.
Solution Approach 2:
The patent introduces an optical imaging system as an intermediary between the laser arrays and the workpiece. This optical system performs diffuse imaging that overlaps multiple laser array outputs, acting as a mediator to homogenize the energy distribution across the working plane while preserving the redundancy benefits of multiple arrays.
3Productivity
If addressable arrays with one laser per pixel are used, then processing speed increases, but device complexity and service costs increase
Solution Approach 1:
The patent makes each laser array multi-functional by having it illuminate multiple pixel areas simultaneously through optical imaging. Instead of each laser array being dedicated to a single pixel, the same array contributes to multiple pixels, reducing the total number of arrays needed while maintaining high processing speed through parallel illumination of multiple areas.
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 system achieves more reliable and efficient 3D printing with improved homogeneity of energy distribution and increased throughput by using multiple semiconductor lasers per pixel, allowing for higher power densities and reduced alignment requirements, thereby minimizing defects and operational costs.
Implementation Method 1
The optical element is adapted to image laser light emitted by the laser arrays, such that laser light of semiconductor lasers of one laser array is imaged to one pixel in a working plane of the laser printing system.
Data Source
AI summary
The invention describes a laser printing system (100) for illuminating an object moving relative to a laser module of the laser printing system (100) in a working plane (180), the laser module comprising at least two laser arrays of semiconductor lasers and at least one optical element, wherein the optical element is adapted to image laser light emitted by the laser arrays, such that laser light of semiconductor lasers of one laser array is imaged to one pixel in the working plane of the laser printing system, and wherein the laser printing system is a 3D printing system for additive manufacturing and wherein two, three, four or a multitude of laser modules (201, 202) are provided, which are arranged in columns (c1, c2) perpendicular to a direction of movement (250) of the object in the working plane (180), and wherein the columns are staggered with respect to each other such that a first laser module (201) of a first column of laser modules (c1) is adapted to illuminate a first area (y1) of the object and a second laser module (202) of a second column (c2) of laser modules is adapted to illuminate a second area (y2) of the object, wherein the first area (y1) is adjacent to the second area (y2) such that continuous illumination of the object is enabled.