Movable Laser Head for Undistorted Beam Processing
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Solution Overview
Problem
Laser materials processing techniques face issues with beam distortion due to deflection mirrors, internal stresses, and crack formation in materials from rapid heating and cooling, as well as inefficient energy use and fume interference in additive manufacturing methods like selective laser melting and sintering.
Innovation Solution
A movable laser head connected via a light guide to a laser beam generating unit, which emits the beam directly without deflection mirrors, equipped with a suction device for fume removal and temperature conditioning to prevent stress and cracking, allowing precise control and efficient energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If deflection mirrors are used to scan the laser beam over the processing field, then the laser beam can be directed to cover a large area, but the beam shape becomes distorted
Solution Approach 1:
The patent removes the deflection mirrors from the optical path entirely. Instead of using mirrors to scan the beam, the system uses a movable laser head that physically translates to different positions, eliminating the beam distortion caused by mirror deflection while maintaining the ability to cover the processing field
Solution Approach 2:
The patent introduces a light guide as an intermediary component that delivers the laser beam directly to the processing location. The light guide acts as a flexible conduit that maintains beam quality while allowing the laser source to remain stationary, with only the light guide tip moving to scan the processing area
2Productivity
If rapid heating and melting is used to process materials efficiently, then productivity increases, but internal stresses and crack formation occur
Solution Approach 1:
The patent employs a suction device that operates concurrently with the laser processing to remove fumes and combustion gases as they are generated. This preliminary action of fume removal prevents interference with the laser beam and maintains processing efficiency while allowing controlled heating rates
Solution Approach 2:
The system uses periodic or pulsed laser processing combined with intermediate cooling periods, allowing the material to undergo controlled thermal cycles. This periodic action enables efficient processing while providing intervals for stress relief and preventing crack formation through controlled thermal management
3Manufacturing precision
If laser beam energy is concentrated for precise processing, then manufacturing precision improves, but energy loss increases due to fume interference
Solution Approach 1:
The patent converts the harmful effect of fume generation into a beneficial process feature. The suction device is strategically positioned to create a controlled flow pattern where fumes are drawn away from the laser path, and the resulting gas flow is used to protect the processing zone and maintain optimal thermal conditions for precise processing
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 solution ensures an undistorted laser beam for precise processing, reduces internal stresses and cracking, and effectively manages fumes, enhancing the accuracy and efficiency of laser materials processing.
Implementation Method 1
lasers are also used in many other materials processing applications for melting or just heating materials
Implementation Method 2
the heat input can result in the generation of fumes; i.e., the generation of combustion gases, evaporation of material
Implementation Method 3
the suction device is adapted to create a suction flow parallel to the direction of the laser beam
Implementation Method 4
The temperature conditioning device allows for local pre- and post-treatment with respect to a temperature treatment prior and/or subsequent to the region being processed with the laser beam, thus making it possible to prevent or reduce stresses and cracks in the material processed
Data Source
AI summary
An apparatus for laser materials processing including a laser (4) for generating a laser beam and a laser head (5) which is movable along at least one spatial direction and is connected to the laser via a light guide, and which emits a laser beam (7) capable of processing a material. The present invention also relates to an apparatus for selective laser melting or selective laser sintering having an apparatus for laser materials processing.