Linear Laser Pixel Array for Stable Metal Powder Melting
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Solution Overview
Problem
Current selective laser melting processes in metal additive manufacturing are limited by the ability to deliver energy to the build surface in a controlled manner, leading to issues such as metal vaporization, melt pool instability, and reduced part accuracy and resolution, especially when multiple laser spots are used.
Innovation Solution
An additive manufacturing system utilizing a linear array of laser energy pixels with uniform power density, where each pixel is independently controllable, allowing for controlled energy delivery and scanning as a single entity, thereby increasing processing rate and maintaining part resolution and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser spots are used to increase processing rate, then productivity improves, but melt pool stability deteriorates and part accuracy decreases
Solution Approach 1:
The patent combines multiple laser spots into a single linear array of laser energy pixels that scan together as one integrated unit. This merging approach maintains the increased energy delivery capability (improving productivity) while ensuring uniform power distribution and consistent melt pool behavior across the entire scan line (maintaining part accuracy and melt pool stability).
Solution Approach 2:
The linear array is segmented into multiple independently controllable laser energy pixels, each delivering precisely controlled energy. This segmentation allows for uniform power density distribution across the entire array while maintaining the ability to process multiple areas simultaneously, thus improving productivity without sacrificing precision.
2Productivity
If laser energy is delivered to melt metal powder, then material processing rate improves, but metal vaporization occurs and melt pool instability increases
Solution Approach 1:
The patent changes the parameter of power density distribution from concentrated (single spot) to uniform (linear array). This uniform distribution across multiple pixels delivers the necessary total energy for high processing rates while preventing localized overheating that causes vaporization and instability, thus improving both productivity and reliability.
3Speed
If traditional multi-spot laser systems are used, then processing speed increases, but energy control precision deteriorates
Solution Approach 1:
The linear array of independently controllable pixels enables precise feedback control of energy delivery to each position along the scan line. This ensures uniform power density and accurate energy placement at high speeds, maintaining both processing speed and energy control precision.
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 system achieves higher effective material processing rates with improved melt pool stability and part resolution by delivering controlled laser power uniformly across the build surface, addressing the limitations of traditional multi-spot laser systems.
Implementation Method 1
Each optical fiber is configured to transmit laser energy from a first end coupled to an associated laser energy source of the two or more laser energy sources and out of a second end
Implementation Method 2
an optics assembly constructed and arranged to shape the laser energy output from each optical fiber to form a rectangular laser energy pixel associated with each laser energy source
Implementation Method 3
exposure of a layer of material on the build surface to the linear array of laser energy pixels melts at least a portion of the layer of material
Implementation Method 4
The metal powder that is scanned with the laser spot is melted and fused into a solid metal structure
Data Source
AI summary
Aspects described herein relate to additive manufacturing systems and related methods. An additive manufacturing system may include two or more laser energy sources and associated optical fibers. An optics assembly may be constructed and arranged to form a rectangular laser energy pixel associated with each laser energy source. Each pixel may have a substantially uniform power density, and the pixels may be arranged to form a linear array of laser energy pixels on a build surface with no spacing between the pixels. Exposure of a portion of a layer of material on the build surface to the linear array of laser energy pixels may melt the portion of the layer.