Multi-Station Laser Beam Splitting for Faster 3D Printing
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Solution Overview
Problem
Current additive manufacturing systems face inefficiencies in material supply and processing precision, particularly in managing multiple manufacturing stations and laser beam distribution, which affects the speed and accuracy of three-dimensional workpiece creation.
Innovation Solution
The system incorporates a plurality of manufacturing stations with a laser beam coupling device that splits an input laser beam into partial beams, guided through beam paths to multiple scan devices, allowing for precise control of beam parameters and simultaneous use of multiple laser beams for accurate and efficient material processing across multiple workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single laser beam is used for manufacturing, then the system is simple, but the productivity is low due to sequential processing of workpieces
Solution Approach 1:
The system segments a single laser beam into multiple partial beams using beam splitting devices, allowing simultaneous processing of multiple workpieces or multiple areas of a workpiece. This segmentation enables parallel manufacturing operations, significantly improving productivity while maintaining a relatively simple system architecture based on a single laser source.
2Productivity
If multiple laser beams are used for simultaneous processing, then the productivity increases, but the device complexity increases due to multiple laser sources and beam management systems
Solution Approach 1:
The system merges the functions of multiple laser sources into a single laser source by using beam splitting devices to distribute the single beam to multiple manufacturing stations. This combining approach achieves the productivity benefits of multiple beams while avoiding the complexity of managing multiple independent laser sources, their synchronization, and individual beam control systems.
3Device complexity
If material supply devices are reduced, then the device complexity decreases, but the manufacturing precision may be affected due to limited material supply capability
Solution Approach 1:
The system implements a universal material supply approach where a single material supply device serves multiple manufacturing stations. The material supply system is designed to distribute material efficiently to multiple beam paths, maintaining manufacturing precision through coordinated material delivery that matches the simultaneous processing requirements of multiple workpieces or areas.
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 configuration enables rapid and precise manufacturing of complex workpieces with reduced material supply devices, allowing for simultaneous processing of multiple workpieces with varying parameters, improving both speed and accuracy in additive manufacturing.
Implementation Method 1
a laser beam coupling device (24) receiving a laser beam (26) as an input beam and a plurality of beam paths (30) along which a light of the input beam (26) is guided, the beam paths (30) being directed from the laser beam coupling device (24) to the manufacturing stations (2)
Data Source
AI summary
An additive manufacturing system includes a plurality of manufacturing stations each performing a manufacturing step, a laser beam coupling device receiving a laser beam as an input beam, and a plurality of beam paths along which a light of the input beam is guided. The beam paths are directed from the laser beam coupling device to the manufacturing stations.