Liquid-Jet Guided Laser 3D Shaping With Z-Depth Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional laser-based subtractive manufacturing for 3D shaping of workpieces is limited by inadequate control over the z-direction of material ablation, leading to imprecise and slow processing, which hinders the ability to achieve complex 3D shapes efficiently.
Innovation Solution
An apparatus and method utilizing a pulsed laser beam coupled into a fluid jet, with a motion controller for precise 3D positioning and a measuring unit to monitor the z-position of material ablation, allowing for controlled and accurate material removal in the z-direction, enabling fast and precise 3D shaping by adjusting laser pulse energy and position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser machining is used for 3D shaping, then material ablation can be achieved, but the control over z-position and ablation depth is insufficient leading to imprecise processing
Solution Approach 1:
The patent implements a feedback mechanism by measuring the z-position of the fluid jet's point of incidence on the workpiece and using this information to control the laser beam's ablation depth. The measuring unit provides real-time z-position data, which is fed back to the control system to adjust subsequent laser pulses, ensuring precise depth control and compensating for surface irregularities.
Solution Approach 2:
The patent replaces mechanical depth measurement and control systems with an optical/electromagnetic approach. Instead of using mechanical probes or contact-based measurement, the system uses electromagnetic radiation (light) to measure the z-position of the fluid jet's point of incidence, enabling non-contact, high-precision measurement and control.
2Productivity
If conventional laser subtractive manufacturing is used, then material removal can be achieved, but the process is slow and imprecise
Solution Approach 1:
The real-time feedback from the measuring unit allows the control system to make immediate adjustments to the laser parameters, ensuring that each pulse achieves the desired ablation depth without requiring multiple corrective passes. This reduces total processing time while maintaining high precision.
Solution Approach 2:
The system performs preliminary measurement of the z-position before each laser pulse, allowing the control system to pre-calculate the optimal laser parameters for the next ablation step. This preparation in advance prevents delays during the actual machining process and ensures precise depth control from the start.
3Adaptability or versatility
If conventional laser machining apparatus is used, then through-cutting and drilling can be performed, but full 3D shaping into complex final parts is not achievable
Solution Approach 1:
The patent creates a universal machining system that can perform multiple functions: through-cutting, drilling, and full 3D shaping of complex geometries. The key enabling feature is the z-position measurement and feedback control, which allows the same apparatus to precisely control material removal in all three spatial dimensions, transforming it from a limited 2D machining tool to a comprehensive 3D manufacturing 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 approach enables fast, precise, and fully controlled 3D shaping of workpieces, allowing for the creation of complex geometries with high accuracy and efficiency, improving upon conventional methods by providing real-time feedback for optimal material ablation.
Implementation Method 1
The present invention relates to an apparatus for three-dimensional (3D) shaping of a workpiece into a final part by material ablation. The material ablation is effected with a laser beam
Implementation Method 2
a laser beam, preferably a pulsed laser beam, which is guided in a fluid jet onto the workpiece
Data Source
Figure 1
Figure 2(a)~2(c)
Figure 3(1)~3(3)
AI summary
The invention relates to an apparatus 100 for 3D shaping of a workpiece 101 by material ablation with a laser beam 102. The apparatus 100 comprises a machining unit 103, which is configured to provide a pressurized fluid jet 104 onto the workpiece 101 and to couple the laser beam 102 into the fluid jet 104 towards the workpiece 101. Further, the apparatus 100 includes a motion controller 105 configured to set an x-y-z-position of the workpiece 101 relative to the machining unit 103. It also includes a measuring unit 107 configured to measure a z-position of the point of incidence 108 of the pressurized fluid jet 104 on the workpiece 101 in the z-direction.