Multi-Optical Train Module With Shared Window Thermal Alignment
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Solution Overview
Problem
In additive manufacturing, the use of multiple optical trains for steering laser beams can result in differential thermal drift due to temperature differences, leading to misalignment of solidified sections and increased complexity in assembly and thermal management.
Innovation Solution
A module with multiple optical trains is configured to share a single window in the build chamber, featuring a common thermal circuit for cooling and a unified housing, which thermally connects each optical train to maintain uniform temperature and reduce distortion, while allowing for overlapping irradiation volumes to enhance scanning efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple optical trains are used to steer multiple laser beams simultaneously, then build speed and productivity are improved, but differential thermal drift occurs between optical trains leading to misalignment of solidified sections
Solution Approach 1:
The patent merges multiple optical trains into a single integrated module with a common housing and shared cooling circuit. This integration ensures that all optical trains experience the same thermal conditions, eliminating differential thermal drift between them while maintaining the ability to steer multiple laser beams simultaneously for high-speed building
2Adaptability or versatility
If multiple optical trains are physically spaced apart to allow independent scanning zones, then flexibility in scanning different areas is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple optical trains within a single modular housing that integrates all necessary components (optical trains, cooling circuit, mounting interfaces) into one assembly unit. This reduces the number of separate components that need to be assembled and ensures precise relative positioning of optical trains, simplifying installation while maintaining scanning flexibility
Solution Approach 2:
The integrated module design creates a universal component that can be installed in various configurations and positions within the build chamber. The module provides multiple functions (steering multiple laser beams, thermal management, mechanical support) in a single unit, reducing overall system complexity
3Temperature
If each optical train has independent cooling, then thermal management flexibility is improved, but device complexity and potential for thermal imbalance increase
Solution Approach 1:
The patent merges the cooling systems of multiple optical trains into a single common cooling circuit that thermally connects all optical trains. This ensures uniform temperature distribution across all optical components, preventing thermal imbalances while simplifying the thermal management system by reducing the number of independent cooling loops
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 ensures accurate alignment and reduced distortion of laser beams, simplifies the assembly process, and maintains uniform temperature across optical trains, thereby improving the precision and efficiency of the additive manufacturing process.
Implementation Method 1
a common thermal circuit thermally connecting each of the more than one optical trains
Implementation Method 2
The cooling circuit may cool the module in the vicinity of the single aperture common to the more than one optical train
Implementation Method 3
a laser beam is scanned across portions of the powder layer that correspond to a cross-section of the object being constructed. The laser beam melts or sinters the powder to form a solidified layer
Data Source
AI summary
A module for an additive manufacturing apparatus including more than one optical train, each optical train providing a route for a laser beam to pass through the module and including steering optics for steering the laser beam towards the material to be consolidated as part of a layer-by-layer additive manufacturing process. The module is configured to deliver laser beams from the more than one optical trains through a single window in a build chamber of the additive manufacturing apparatus.