3D Printing Laser Scan Modulation for Higher Fusion Rates
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional selective additive manufacturing machines have insufficient productivity due to limitations in the number and cost of laser sources, which pose space and economic challenges when trying to increase productivity.
Innovation Solution
An apparatus with a single laser source and a modulating mirror system that modifies the laser beam's trajectory, allowing for efficient energy distribution and increased fusion rates by introducing modulations onto the main scanning trajectory, thereby enhancing productivity without the need for multiple laser sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of laser sources is increased to increase productivity, then the productivity increases, but the cost increases significantly and space requirements increase
Solution Approach 1:
The patent segments the laser beam path into multiple controllable segments using galvanometric mirrors and modulating mirrors. Each mirror independently controls a portion of the scanning trajectory, allowing a single laser source to effectively cover multiple zones that would traditionally require multiple laser sources. This segmentation of the beam path enables one laser to perform the work of multiple lasers.
Solution Approach 2:
The patent introduces dynamic modulation of the laser beam trajectory through modulating mirrors that can rapidly adjust the beam path in real-time. The galvanometric mirrors provide dynamic scanning control, and the modulating mirrors add additional dynamic modulation capabilities, allowing the single laser source to dynamically adapt its scanning pattern to achieve higher productivity equivalent to multiple static laser sources.
2Productivity
If the number of laser sources is increased to increase productivity, then the productivity increases, but the cost increases significantly
Solution Approach 1:
The patent makes a single laser source perform multiple functions by using it to scan multiple zones and layers through the coordinated action of galvanometric mirrors and modulating mirrors. The single laser source is universally applied to accomplish what would traditionally require multiple dedicated laser sources, thereby reducing the overall system cost while maintaining high productivity.
Solution Approach 2:
The patent introduces optical intermediaries in the form of galvanometric mirrors and modulating mirrors that mediate between the single laser source and the powder bed. These intermediary components enable the laser beam to be dynamically directed to multiple locations, effectively multiplying the productivity of a single laser source without the cost of multiple lasers.
3Productivity
If multiple laser sources are used to increase productivity, then the productivity increases, but the space requirements increase
Solution Approach 1:
The patent adds temporal and angular dimensions to the laser scanning process through the use of modulating mirrors. Instead of simply adding more laser sources in spatial dimensions, the invention exploits the temporal dimension (rapid modulation) and angular dimension (beam steering) to achieve multiple zone coverage with a single laser source, thereby maintaining high productivity while reducing spatial footprint.
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 apparatus achieves a significant increase in surface fusion rates and specific surface productivity while maintaining a compact design and reducing costs, with improved control over cooling dynamics and energy deposition, thus overcoming the limitations of conventional systems.
Implementation Method 1
a modulating mirror suitable for reflecting the laser beam emitted by the laser source and for directing it towards the scanning device
Implementation Method 2
a first scanning mirror and/or a second scanning mirror, the scanning device being suitable for modifying the orientation of the first scanning mirror with respect to a first scanning rotational axis and/or of the second scanning mirror with respect to a second scanning rotational axis
Implementation Method 3
a laser source suitable for emitting a laser beam
Implementation Method 4
selective additive manufacturing consists of producing three-dimensional objects by consolidation of selected zones on successive strata of powdery material... by total or partial selective fusion performed with a consolidation source
Data Source
AI summary
An apparatus for manufacturing a three-dimensional object by selective additive manufacturing comprises: a support (140) suitable for supporting at least one layer (150) of additive manufacturing powder, a laser source (110) suitable for emitting a laser beam (111), a scanning device (130) suitable for directing the laser beam onto the powder layer so as to scan at least a portion of the powder layer, and a device (120) for modulating the scanning trajectory, arranged upstream of the scanning device, the modulating device comprising a modulating mirror (121) suitable for reflecting the laser beam emitted by the laser source and for directing it towards the scanning device, the angle of incidence of the laser beam emitted by the laser source on the modulating mirror being between 20 and 45°.