Laser Beam Scanner with Fiber Termination Optic for Multi-Laser Scanning
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Solution Overview
Problem
The existing laser beam scanners for additive manufacturing face challenges in delivering high laser power efficiently and accurately to the powder bed, particularly due to the complexity and cost associated with individual optical channels for each laser beam, which limits the speed and productivity of the process.
Innovation Solution
A laser beam scanner design that aligns and fuses the output ends of optical fibers with a termination optic, using a holder with channels and lenses for collimation and focusing, and incorporates tiltable mirrors and a dynamic focussing optic to direct and maintain high-energy laser beams across the powder bed, allowing for rapid and precise scanning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple independent laser sources with individual optical channels are used to increase laser power delivery, then laser power and productivity are improved, but device complexity and cost increase significantly
Solution Approach 1:
Multiple optical fibers carrying laser beams from different laser sources are merged into a single termination optic. The holder aligns multiple fiber output ends with the termination optic, which then directs all beams through a single optical channel to the scanning mirrors and focusing lens, eliminating the need for multiple separate optical channels while maintaining high laser power delivery capability
Solution Approach 2:
The termination optic serves multiple functions: it receives laser beams from multiple optical fibers, aligns them to a common optical axis, and directs them through the scanning system. This single component performs what would traditionally require multiple separate optical channels, reducing system complexity while maintaining versatility in handling multiple laser beams
2Power
If traditional multi-laser systems with individual optical channels are used, then laser power delivery is improved, but alignment time and servicing requirements increase
Solution Approach 1:
Multiple optical fibers are bundled together and terminated onto a single termination optic using the holder assembly. This merging approach requires only one alignment operation to establish the optical axis, compared to multiple separate alignment operations that would be needed for individual optical channels, dramatically reducing alignment time and simplifying manufacturing
Solution Approach 2:
The holder is designed with pre-formed channels that guide and pre-align the optical fibers to the termination optic. This preliminary alignment structure is built into the holder during manufacturing, so that when fibers are inserted and terminated, they are already positioned correctly, eliminating the need for time-consuming post-assembly alignment adjustments
3Productivity
If more lasers are added to increase productivity, then manufacturing speed is improved, but physical space requirements and device complexity increase
Solution Approach 1:
Multiple laser beams from different sources are combined into a single optical path through the termination optic. This allows multiple lasers to be delivered through one compact beam delivery channel instead of requiring separate channels for each laser, dramatically reducing the physical space needed while maintaining the ability to deliver high laser power for increased productivity
Solution Approach 2:
The holder channels are arranged in a three-dimensional configuration that allows multiple optical fibers to be densely packed and routed to the termination optic. This spatial arrangement in multiple dimensions enables more lasers to be integrated into the system without proportionally increasing the footprint of the beam delivery system
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 solution enables increased laser power delivery with minimal energy loss, allowing for faster and more accurate scanning of laser beams across the powder bed, thereby enhancing the productivity and efficiency of additive manufacturing processes without the need for multiple expensive optical channels.
Implementation Method 1
a plurality of optical fibres for delivering a plurality of laser beams from a laser source
Implementation Method 2
a termination optic aligned to direct the laser beams from output ends of the optical fibres to the laser beams positioning optic
Implementation Method 3
The laser beams positioning optic is movable relative to the fibre termination optic to scan the laser beams across a working surface
Data Source
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AI summary
This invention concerns a laser beam scanner comprising a laser beams positioning optic (120), a plurality of optical fibres (121) for delivering a plurality of laser beams (122a) and a fibre termination optic (123a) aligned to direct the laser beams from output ends of the plurality of optical fibres (121) to the laser beams positioning optic (120). The laser beams positioning optic (120) is movable relative to the fibre termination optic (123a) to scan the laser beams (122a) across a working surface (124).