Laser 3D Printing Light Spot Orthopedic Device
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Solution Overview
Problem
In laser 3D printing, the inconsistency of the focused light spot within the scanning plane affects the quality of the printed products, leading to issues like holes, over-burning, and spheroidization, which are not adequately addressed by prior technologies.
Innovation Solution
A method and system that measures the projection characteristics of each spot within the scanning plane to set compensation quantities for a light spot orthodontic device, ensuring consistent light spot sizes, combined with dynamic matching of the orthodontic device and scanning device, and controlled laser pulse width for sintering and polishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If laser beam scans for large format 3D printing, then the printing area is increased, but the size of the focused light spot becomes inconsistent within the scanning plane
Solution Approach 1:
The patent applies dynamics by making the optical system adjustable through a light spot orthodontic device that can dynamically modify the light spot shape and size. The device includes movable components that can be adjusted in real-time during the scanning process to compensate for distortions, transforming a static optical system into a dynamic one that adapts to maintain consistent light spot dimensions across the entire scanning plane.
Solution Approach 2:
The patent implements parameter changes by modifying the shape and size parameters of the light spot through the orthodontic device. By adjusting the optical parameters (such as focal length, beam diameter, and convergence angle) of the cylindrical lenses and imaging system, the system compensates for the non-uniform light spot distribution caused by large format scanning, ensuring consistent printing quality across the expanded area.
2Device complexity
If conventional laser sintering is used, then the process is simple, but defects like holes, over-burning and spheroidization occur
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-configuring the light spot orthodontic device compensation parameters based on the scanning pattern and optical system characteristics. Before actual printing begins, the system performs measurement and characterization of the light spot distribution, then sets up the compensation quantities in advance. This preliminary preparation enables the system to counteract potential defects before they occur during the sintering process.
Solution Approach 2:
The patent implements feedback by measuring the projection characteristics of each spot within the scanning plane to obtain deformation quantities, then using this measurement data to set compensation quantities for the light spot orthodontic device. This closed-loop feedback mechanism allows the system to continuously monitor and adjust the light spot characteristics, correcting deviations that would otherwise lead to printing defects like holes, over-burning, and spheroidization.
3Productivity
If laser pulse width is not controlled, then the sintering process is fast, but density is reduced due to over-burning and spheroidization
Solution Approach 1:
The patent applies periodic action by using pulsed laser sintering instead of continuous laser irradiation. The laser operates in periodic pulses with controlled duration and intervals, allowing the material to be heated and sintered in discrete steps. This periodic action prevents excessive heat accumulation that would cause over-burning and spheroidization, while maintaining high productivity through optimized pulse frequency and duty cycle.
Solution Approach 2:
The patent implements parameter changes by dynamically adjusting the laser pulse width parameter during the sintering process. By controlling and varying the pulse duration, the system optimizes the energy input to achieve complete sintering without excessive melting. The pulse width is adjusted based on material properties, layer thickness, and position within the scanning plane, ensuring consistent density while maintaining fast processing speed.
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 ensures consistent light spot sizes, improves printing quality by reducing defects like holes and over-burning, and increases the density of the printed components.
Implementation Method 1
Laser sintering technology adopts the principle that powder material is sintered under laser irradiation and is formed layer-by-layer under control of a computer
Implementation Method 2
performing laser-induced shock wave impact to a 3D sintered component by using a short pulse width laser
Data Source
AI summary
A laser 3D printing method with orthopedic function, comprising the following steps: step one, measuring a projection characteristic of each spot within a scanning plane, to obtain a deformation quantity of a focused light spot at the each spot within the scanning plane before rectifying; step two, setting compensation quantities of the each spot within the scanning plane of a light spot orthopedic device according to the measuring result of the step one, so that the size of the focused light spot at the each spot within the scanning plane is consistent; step three, turning on the laser, and dynamically matching the light spot orthopedic device and a scanning device to perform the laser 3D printing. The laser 3D printing method and system thereof with orthopedic function could ensure the size of the focused light spot is consistent within the scanning plane, thereby ensuring the quality of 3D printing.