Multi-Beam Laser Optics for Omnidirectional Additive Machining
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Solution Overview
Problem
High power laser additive manufacturing systems face limitations in omnidirectional processing due to conventional beam delivery optics that do not allow for flexible beam distribution and axial space for centric feed tool geometry, restricting processing capabilities and beam quality at high powers.
Innovation Solution
A multiple optical fiber core array system that spatially separates and focuses laser beams into a radial array surrounding a central tool axis, enabling access for centric material feed and flexible beam delivery, with optional Schwarzschild, catadioptric, or beam redirecting optical systems to accommodate filler material and enhance processing flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional beam delivery optics are used, then laser processing can be performed, but omnidirectional processing capability is limited and axial space for centric feed tool geometry is restricted
Solution Approach 1:
The laser beam is divided into multiple separate beams using beam splitting optics, allowing each beam to be independently directed to different locations on the workpiece. This segmentation enables omnidirectional processing capability while maintaining flexibility in beam delivery configuration.
Solution Approach 2:
The patent transitions from a single-axis beam delivery system to a multi-dimensional beam array system. Multiple beams are arranged in spatial arrays that can be dynamically configured to provide processing capability in multiple directions simultaneously, enabling omnidirectional processing.
2Power
If high power laser systems are used, then processing speed and capability are improved, but beam quality deteriorates and processing flexibility is reduced
Solution Approach 1:
High power laser energy is divided into multiple lower-power beams through beam splitting. Each individual beam maintains better quality parameters while collectively delivering high total power to the workpiece, resolving the trade-off between power and beam quality.
Solution Approach 2:
Beam splitting optics and arrayed delivery systems act as intermediaries between the high power laser source and the workpiece. These intermediaries distribute the high power into multiple manageable beams that can be precisely controlled and focused, maintaining beam quality while delivering high total power.
3Adaptability or versatility
If centric axial feed material system is used, then omnidirectional processing is enabled, but beam delivery path is obstructed by feed mechanics
Solution Approach 1:
The laser beam is segmented into multiple paths that circumvent the central feed material delivery axis. By distributing beams around the periphery, the system enables centric feed material access while avoiding obstruction of the beam paths by feed mechanics.
Solution Approach 2:
The beam delivery system moves from a centralized on-axis configuration to a distributed off-axis array configuration. Multiple beams are delivered from peripheral locations surrounding the central feed axis, enabling both centric material feed and unobstructed beam delivery in three-dimensional space.
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 solution allows for efficient, high-power, omnidirectional laser processing with improved beam quality and access for centric feed mechanics, enabling faster and more versatile processing capabilities beyond the limitations of traditional systems.
Implementation Method 1
An optical system receives the multi-beam array, spatially separates the multiple beams into multiple processing beams, arranges the multiple processing beams in a processing output array surrounding a central tool axis, and focuses each beam to one or more processing spots at or near a work surface
Implementation Method 2
irradiating one or more of the work surface and the wire with the processing spots, and melting the filler material at the work surface such that material from the wire is added to the workpiece
Data Source
AI summary
Laser processing systems and methods image a multiple core array to a work surface in a multiple processing beam array. An optical system separates processing beams and converges the beams toward the work surface and focuses each beam of the array at or near the work surface. A central axis with access for filler material flow to the work surface is provided. The processing beam array and central filler material feed provide omni-directional additive laser processing capability.