Optical Laser Correction for Thermal Beam Distortion
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Solution Overview
Problem
Laser-based manufacturing processes face challenges due to atmospheric distortions caused by temperature differences and refractive index variations when a laser beam interacts with materials, leading to beam defocusing and reduced energy delivery to target locations, which can increase manufacturing time and inefficiency.
Innovation Solution
An optical correction system dynamically adjusts laser beams to counteract atmospheric distortions by applying pre-distortion to subsequent beams passing through affected regions, using phase-front shape adjustments and real-time sensor data to ensure accurate targeting and energy delivery without retargeting or power increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser beams are directed through atmospheric regions heated by previous beams, then manufacturing throughput can be increased by processing adjacent locations, but beam defocusing and energy delivery reduction occur due to refractive index variations
Solution Approach 1:
The patent applies pre-distortion to laser beams before they traverse atmospheric regions that have been heated by previous beams. The optical correction system modifies the beam's wavefront in advance to counteract the expected refractive index variations, ensuring the beam remains focused despite passing through thermally distorted atmospheric paths between adjacent target locations
Solution Approach 2:
The system uses real-time sensing of atmospheric conditions and beam characteristics to dynamically adjust optical correction parameters. Sensors detect refractive index variations and temperature gradients in the atmospheric path, and this feedback is used to modify the pre-distortion applied to subsequent beams, maintaining focus accuracy throughout the manufacturing process
2Manufacturing precision
If laser power is increased to compensate for energy loss due to atmospheric distortion, then beam focus can be maintained, but manufacturing time increases due to delays between process steps
Solution Approach 1:
Instead of increasing laser power or waiting for atmospheric conditions to stabilize, the system pre-distorts subsequent beams to proactively compensate for expected atmospheric distortions. This allows continuous processing of adjacent locations without power increases or time delays, as the optical correction is applied in advance based on predicted thermal conditions
3Manufacturing precision
If optical correction is applied to subsequent beams, then beam focus and energy delivery are maintained through distorted atmospheric regions, but system complexity increases
Solution Approach 1:
The patent introduces an optical correction system with pre-distortion capability as an intermediary between the laser source and the material. This intermediary component actively compensates for atmospheric distortions by modifying beam wavefronts, maintaining energy delivery accuracy without requiring fundamental changes to the laser or material processing setup
Solution Approach 2:
The system replaces mechanical approaches (such as physically moving components or waiting for thermal equilibrium) with optical field-based correction. By using wavefront modulation and phase correction techniques, the system achieves focus maintenance through optical means rather than mechanical adjustments or time-based thermal management
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 enhances manufacturing efficiency by reducing delays between process steps, maintaining beam focus, and improving throughput by allowing adjacent processing without significant delays or power overcompensation, thus optimizing laser-based manufacturing processes.
Implementation Method 1
a laser can be used to heat a material, to promote curing of a material, to fuse or weld materials, to cut materials
Implementation Method 2
differences in refractive indexes between the laser device and the material... refractive index of the atmosphere to vary along the path that the beam of light traverses. The differences in refractive index along the path cause distortion of the beam of light
Implementation Method 3
an optical system coupled to the one or more laser devices and configured to perform optical correction of the light
Data Source
AI summary
A method of forming an object from a material includes directing a first beam of light toward a first target location of the material to define a first portion of the object. The method also includes, after directing the first beam of light toward the first target location, determining an optical correction to be applied by an optical system. The optical correction is based on an atmospheric change in an atmospheric distortion region proximate the first target location due, at least in part, to interaction of the first beam of light and the material. The method further includes directing a second beam of light toward a second target location of the material to define a second portion of the object. The second beam of light is directed through at least a portion of the atmospheric distortion region while the optical correction is applied.