Linear Steering Optics for Compact Beam Deflection in 3D Printing

Solution Overview

Problem

Existing energy beam directing systems, such as galvanometers, are bulky and cause field distortion, limiting the effectiveness of focal optics and scalability in additive manufacturing machines.

Innovation Solution

An optical translation system that translates a steering optic via linear motion actuation to deflect the energy beam, eliminating the need for rotational galvanometers and allowing for co-linear arrangement of components, reducing size and improving precision and accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If rotational galvanometers are used to direct the energy beam, then the beam can be deflected, but the system becomes bulky and causes field distortion

Engineering Contradiction:

Improvebeam deflection capabilityVSAvoidsystem size

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The patent replaces the rotational galvanometer mechanism with a linear motion translation system. Instead of rotating mirrors to deflect the beam, the system uses linear actuators to translate steering optics along a linear path, eliminating the bulky rotational mechanism while maintaining beam deflection capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent inverts the conventional approach by using linear translation instead of rotational motion. Rather than rotating the steering optic to change beam angle, the steering optic is translated linearly, and the angular deflection is achieved through the optical geometry of the translated position.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of operation

If rotational galvanometers are used to direct the energy beam, then the beam can be deflected, but field distortion occurs that limits effectiveness of focal optics

Engineering Contradiction:

Improvebeam deflection capabilityVSAvoidbeam positioning accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent replaces the rotational galvanometer mechanism with a linear motion translation system. Instead of rotating mirrors to deflect the beam, the system uses linear actuators to translate steering optics along a linear path, eliminating the bulky rotational mechanism while maintaining beam deflection capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs dynamic translation of the steering optic along a linear path, allowing real-time adjustment of the beam angle without the mechanical constraints of rotation. This dynamic linear motion system provides smoother, more precise control over beam positioning and reduces field distortion.

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If traditional directing systems are used, then beam direction can be controlled, but the packaging size is increased

Engineering Contradiction:

Improvebeam direction controlVSAvoidpackaging size

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The patent replaces the rotational galvanometer mechanism with a linear motion translation system. Instead of rotating mirrors to deflect the beam, the system uses linear actuators to translate steering optics along a linear path, eliminating the bulky rotational mechanism while maintaining beam deflection capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent segments the beam direction control function into independent linear translation stages, allowing compact arrangement of the translation components and reducing the overall packaging volume compared to a single large rotational galvanometer assembly.

Inventive Principle:

Principle #1Segmentation

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 enables smaller packaging, improved precision, and reduced distortion, enhancing the effectiveness of energy beam direction in additive manufacturing processes.

Implementation Method 1

An optical translation system that translates a steering optic via linear motion actuation to deflect the energy beam

Methodology Applied

Scientific EffectLinear motion actuation: Linear Motor

Implementation Method 2

a steering optic positioned to receive one of the plurality of energy beams from the one or more energy beam generators

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS12569913B2Energy beam directing device

Publication Date: 2026.03.10 GENERAL ELECTRIC CO

AI summary

An additive manufacturing machine and an energy beam system including an energy beam generator configured to output an energy beam through a first optical element along a first direction is provided. The energy beam system includes an optical translation system positioned to receive the energy beam through a steering optic. The steering optic is positioned within a translator apparatus. The translator apparatus is configured to translate the steering optic along a plane perpendicular to the first direction.