Light Recycling Optics for Higher-Throughput Additive Manufacturing
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Solution Overview
Problem
In laser-based additive manufacturing systems, a significant amount of light is wasted due to the rejection of unwanted light patterns, leading to reduced efficiency and increased energy costs.
Innovation Solution
An optical system that recycles and re-uses rejected light by combining and homogenizing it with the original beam, allowing it to be reintroduced into the system, thereby maintaining high throughput rates and increasing light intensity proportional to the rejected energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If light is rejected by the liquid crystal light valve to create the desired pattern, then the desired polarization state is achieved, but a significant amount of light energy is wasted
Solution Approach 1:
The patent recovers the rejected light by capturing the unwanted polarization state from the light valve and redirecting it through optical elements (beam splitter, mirrors) back to the light source or into the processing path, thereby recovering energy that would otherwise be discarded to a beam dump
Solution Approach 2:
The patent converts the harmful waste light into a beneficial resource by using the rejected polarization state as additional light intensity that can be reused in the additive manufacturing process, transforming energy loss into productivity enhancement
2Productivity
If high intensity light is used to maintain high throughput rates, then productivity increases, but energy costs increase
Solution Approach 1:
The patent implements a feedback loop where the rejected light is captured and fed back into the optical path, creating a recycling system that maintains high light intensity at the build platform without proportionally increasing energy consumption from the light source
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 effectively redistributes the light power, increasing the intensity of the light directed at the build platform, reducing energy costs, and enabling faster print rates and higher material conversion rates without compromising efficiency.
Implementation Method 1
An optical system that recycles and re-uses rejected light by combining and homogenizing it with the original beam
Implementation Method 2
combining and homogenizing it with the original beam
Implementation Method 3
Liquid crystal based light valves allow for the spatial modulation of transmitted or reflected light by rotating the electromagnetic wave polarization state
Data Source
AI summary
A method and an apparatus pertaining to recycling and reuse of unwanted light in additive manufacturing can multiplex multiple beams of light including at least one or more beams of light from one or more light sources. The multiple beams of light may be reshaped and blended to provide a first beam of light. A spatial polarization pattern may be applied on the first beam of light to provide a second beam of light. Polarization states of the second beam of light may be split to reflect a third beam of light, which may be reshaped into a fourth beam of light. The fourth beam of light may be introduced as one of the multiple beams of light to result in a fifth beam of light.