Monolithic Multi-Optics Scanner Head for Offline Pre-Calibration
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Solution Overview
Problem
Existing 3D printing systems face inefficiencies due to the need for frequent recalibration and maintenance of individual scanner heads, particularly when replacing beam entry windows, which leads to significant downtime and reduced productivity.
Innovation Solution
The integration of multiple optics into a monolithic scanner head housing allows for streamlined calibration and maintenance, as the entire package can be pre-calibrated offline, reducing the need for recalibration after installation and enabling easier replacement of components like beam entry windows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If individual scanner heads are used with separate beam entry windows, then each scanner can be independently maintained, but the system requires frequent recalibration and significant downtime when replacing windows
Solution Approach 1:
The patent combines multiple scanner heads and their beam entry windows into a single integrated scanner head assembly. This merging allows the entire assembly to be pre-calibrated as one unit and replaced atomically, eliminating the need for post-replacement recalibration and reducing downtime significantly.
Solution Approach 2:
The scanner head assembly is pre-calibrated offline before installation in the 3D printing system. This preliminary calibration action ensures that when the assembly is installed or replaced, no additional recalibration is needed, thus eliminating recalibration downtime.
2Adaptability or versatility
If multiple individual scanner heads are installed in the build chamber, then each can process different laser beams, but each requires its own beam entry window and calibration
Solution Approach 1:
The patent integrates multiple scanner heads sharing common beam entry windows and optical paths into a single scanner head assembly. This merging reduces the total number of beam entry windows from multiple individual windows to a shared set, simplifying the system while maintaining the ability to process multiple laser beams simultaneously.
Solution Approach 2:
The integrated scanner head assembly serves multiple functions: it can process multiple laser beams simultaneously, provide shared beam entry windows for all scanners, and maintain a single calibration system that applies to all scanning operations within the assembly.
3Reliability
If beam entry windows are replaced frequently due to degradation and soot accumulation, then optical quality can be maintained, but the entire system must undergo full optical calibration each time
Solution Approach 1:
The beam entry windows are integrated into the scanner head assembly as a unified component. When the windows degrade or accumulate soot, the entire assembly is replaced as one unit that has been pre-calibrated, eliminating the need for post-replacement calibration and reducing productivity loss.
Solution Approach 2:
The scanner head assembly with beam entry windows is pre-calibrated offline before installation. This preliminary calibration ensures that even when windows are replaced frequently, the pre-calibrated assembly can be installed without requiring additional calibration time, thus maintaining productivity.
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 reduces printer downtime, enhances productivity by minimizing maintenance intervals, and allows for improved thermal management and process monitoring without compromising beam quality.
Implementation Method 1
The monolithic multi-optics scanner head housing further comprises a conformal channel with a channel configured for thermal management through the multiple sets of galvos.
Implementation Method 2
a conformal channel with a channel configured for thermal management through the multiple sets of galvos
Implementation Method 3
each set of galvo further comprises a set of printed—in radiator fins, radiator structure, or heat exchangers for thermal management of the multiple sets of galvos
Implementation Method 4
Each set of galvos receives a laser and redirects the laser using a mirror.
Data Source
AI summary
Apparatus and system for optimizing package of scanner heads is disclosed. An apparatus in accordance with an aspect of the present disclosure comprises a monolithic multi-optics scanner head housing configured to receive multiple sets of galvanometer mirror scanners (galvo) and a beam entry window. Each set of galvos receives a laser and redirects the laser using a mirror.