Multi-Laser Additive Manufacturing Tilted Focal Plane
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Solution Overview
Problem
Current additive layer manufacturing processes using a single laser spot are inherently slow and cannot achieve higher speeds without sacrificing surface finish, accuracy, or material quality, as increasing power or scan speed can lead to vaporization of metals or insufficient melting.
Innovation Solution
The use of at least two laser beams with tilted scanners and lenses to generate a tilted focal plane, allowing simultaneous scanning over a common planar field without duplicating work, while maintaining power density and spot size, thereby increasing manufacturing speed without compromising build quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single laser spot is used for additive layer manufacturing, then manufacturing precision and surface finish are maintained, but productivity is inherently slow
Solution Approach 1:
The patent divides the single laser beam into multiple separate laser beams (at least two) that scan simultaneously over the planar field. Each laser beam operates independently to process different regions of the layer, effectively segmenting the manufacturing task to increase overall productivity while maintaining the precision characteristics of individual laser spots.
Solution Approach 2:
The patent introduces a tilted scanner that creates a tilted focal plane, adding a dimensional aspect to the laser scanning system. This tilted configuration allows multiple laser beams to operate simultaneously at different angles and positions across the planar field, enabling parallel processing without compromising the focused energy delivery needed for precise material transformation.
2Productivity
If laser power is increased to speed up manufacturing, then productivity increases, but material quality deteriorates due to vaporization
Solution Approach 1:
By segmenting the manufacturing task across multiple laser beams, each beam can operate at appropriate power levels for controlled melting without excessive energy input. The distributed approach allows the system to achieve higher overall productivity through parallel processing rather than relying on a single high-power beam that would cause vaporization and compromise material quality.
3Productivity
If scan speed is increased to improve productivity, then manufacturing speed increases, but manufacturing precision deteriorates due to insufficient melting
Solution Approach 1:
The segmentation of the build area into multiple zones processed by separate laser beams allows each beam to maintain optimal scan speeds for precise melting. Rather than requiring one laser to cover the entire area at high speed (which would reduce dwell time and melting quality), multiple beams can operate at lower, more controlled speeds in parallel, ensuring adequate energy delivery to each processed region.
4Productivity
If multiple laser beams are used to increase productivity, then manufacturing speed increases, but device complexity increases
Solution Approach 1:
The patent employs multiple laser beams that share common scanning infrastructure and control systems. The scanners and focal plane assembly serve universal functions for all laser beams, reducing the need for completely separate systems for each beam. This multi-functional approach allows parallel processing while minimizing the increase in overall device complexity through shared components and integrated control.
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 faster additive layer manufacturing while maintaining high build quality, precision, and accuracy, allowing for the production of parts at approximately twice the speed of traditional methods without sacrificing surface finish or material properties.
Implementation Method 1
This invention relates to apparatus and methods for additive layer manufacturing using a focused beam of laser energy selectively directed to a planar focal plane adjacent a layer of powder or liquid to carry out a transformation where it strikes—such as a photo polymerisation, sintering or melting of powders
Implementation Method 2
such as a photo polymerisation, sintering or melting of powders thereby building a three dimensional part layer by layer
Implementation Method 3
photo polymerisation, sintering or melting of powders thereby building a three dimensional part layer by layer
Implementation Method 4
said at least one scanner is provided with a lens arranged to generate a focal plane tilted with respect to that scanner
Data Source
AI summary
A method is for additive layer manufacturing an article from a material which can be rendered solid locally by the application of a focused beam of laser radiation. The method includes providing at least two laser beams, providing a scanner for each laser beam for scanning each laser beam over an entire planar field, providing a support moveable step wise to support material within the field, scanning the laser beams simultaneously but separated over the field to render solid the desired portions of material contained in the field to perform a manufacturing cycle and stepping the support after each cycle. At least one scanner is tilted with respect to the common planar field, and the method further includes the step of tilting the focal plane of the laser beam from the said at least one scanner.