Multi-Distribution Laser Beam Shaping for Fast, Precise Workpiece Processing
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Solution Overview
Problem
Existing laser processing methods face challenges in increasing processing speed without compromising quality, as simply increasing average laser power leads to heat accumulation, material vaporization, or destruction due to inadequate temporal and spatial distribution of laser radiation.
Innovation Solution
A device with a beam shaping unit that generates multiple intensity distributions of laser radiation, allowing for efficient processing by distributing energy over a larger area and adjusting intensity to maintain high spatial resolution, enabling faster processing without quality reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the average laser power is increased to accelerate laser processes, then the processing speed is improved, but heat accumulation effects occur that reduce processing quality or destroy the workpiece
Solution Approach 1:
The laser beam is segmented into multiple sub-beams by the beam shaping unit, distributing the total laser power across multiple spatial locations. This segmentation prevents heat accumulation at any single point while maintaining high overall processing speed, as each sub-beam processes a portion of the workpiece simultaneously
Solution Approach 2:
The invention transitions from a single-point processing approach to a multi-point parallel processing approach by shaping the laser beam into multiple intensity distributions. This dimensional change in beam configuration allows simultaneous processing of multiple areas, increasing productivity without compromising quality through localized heat accumulation
2Productivity
If the average laser power is increased in selective laser melting, then the processing speed is improved, but material evaporation effects and excessive temperature gradients occur that reduce processing quality
Solution Approach 1:
The beam shaping unit creates different intensity distributions across different regions of the workpiece, with each region receiving optimized laser power density. This local quality adjustment prevents excessive temperature gradients and material evaporation by tailoring the energy distribution to match the specific processing requirements of each area
Solution Approach 2:
The invention dynamically changes the spatial distribution parameter of laser radiation by generating multiple intensity distributions. This parameter change allows the system to maintain optimal energy density for melting without exceeding thresholds that cause evaporation or excessive temperature gradients, thereby improving both speed and quality
3Manufacturing precision
If the laser beam is moved across the workpiece using scanning systems to achieve temporal and spatial distribution, then the processing quality is maintained, but the dynamics of scanning systems become insufficient to achieve sufficient processing speed
Solution Approach 1:
Instead of moving a single laser beam across the workpiece sequentially, the beam shaping unit segments the beam into multiple sub-beams that process different areas simultaneously. This eliminates the speed limitation of scanning systems by performing parallel processing across multiple spatial locations
Solution Approach 2:
The invention replaces the mechanical scanning system with an optical beam shaping approach. Instead of physically moving the laser beam or workpiece at high speeds, the system uses optical elements to create multiple intensity distributions, substituting mechanical motion with optical manipulation to achieve faster 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 enables a significant increase in processing speed, allowing for faster material removal and precise structure creation, with acceleration factors ranging from 2 to 10, while maintaining high processing quality.
Implementation Method 1
a beam shaping unit which is inserted between the laser radiation source and the receiving area into the beam path of the laser radiation generated by the laser radiation source and which is configured to generate at least two different predetermined intensity distributions, namely at least a first intensity distribution and a second intensity distribution, of the laser radiation on the workpiece by local modulation of the laser radiation
Implementation Method 2
a laser radiation source, a receiving area for receiving a workpiece to be processed
Data Source
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AI summary
The present invention relates to a device for processing a workpiece (24) by irradiation by means of laser radiation. In this case, the device comprises a laser radiation source (10), an accommodating region (22) for accommodating a workpiece (24) to be processed, a beam shaping unit (30), which is inserted between laser radiation source (10) and accommodating region (22) into the beam path of the laser radiation generated by the laser radiation source (10) and is configured to generate at least two different predetermined intensity distributions of the laser radiation on the workpiece (24) by local modulation of the laser radiation, and a movement unit (50) configured to bring about a movement of the laser radiation generated by the laser radiation source (10) on a workpiece (24) arranged in the accommodating region (22). The present invention likewise relates to a method for processing a workpiece (24) by irradiation by means of laser radiation. With the device according to the invention and the method according to the invention, respectively, higher processing rates are achievable in comparison with those systems known from the prior art.