Multi-wavelength Laser Beam Combining Optics for Composite Material Processing
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Solution Overview
Problem
Conventional laser processing systems are limited in their ability to effectively process materials with composite structures, as they typically employ a single laser beam with unsuitable characteristics for multiple materials, leading to damage of certain materials and inability to combine laser beams with different wavelengths and focal planes.
Innovation Solution
The system combines multiple laser beams with different wavelengths and characteristics into a composite beam, using preconditioning, recomposition, beam modification, focusing, alignment, and positioning optics to achieve optimal beam characteristics for processing, allowing for simultaneous and controlled processing of various materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single laser beam is used for processing, then the system structure is simple, but it cannot effectively process materials with composite structures and may damage certain materials
Solution Approach 1:
The patent combines multiple laser beams with different wavelengths into a single composite beam using beam combining optics. This allows the system to process different materials simultaneously with appropriate laser characteristics while maintaining a unified beam delivery path, thus improving material versatility without proportionally increasing system complexity
Solution Approach 2:
The laser processing system is designed to handle multiple material types and processing operations through a single integrated system that can switch between different wavelength lasers. The system provides universal functionality for cutting, marking, welding, and other operations across diverse materials including metals, plastics, and ceramics
2Adaptability or versatility
If laser beams with different wavelengths are combined, then processing capability for composite materials is improved, but beam alignment and focusing becomes more difficult
Solution Approach 1:
The patent introduces intermediary optical components including wavelength-specific beam combining optics and adaptive optics systems that act as mediators between the different wavelength lasers and the workpiece. These intermediaries facilitate precise beam alignment and focusing by compensating for wavelength-specific optical path differences
Solution Approach 2:
The system dynamically adjusts optical parameters such as focal length, beam diameter, and convergence angle based on the specific wavelength combination being used. This parameter optimization ensures that each wavelength component is properly focused on the workpiece plane, overcoming the alignment difficulties inherent in multi-wavelength systems
3Manufacturing precision
If beam characteristics are adjusted to match specific material needs, then processing precision is improved, but system complexity increases
Solution Approach 1:
The patent implements dynamic beam characteristic adjustment through motorized optical element positioning and real-time parameter control. The system can adapt beam wavelength, focal position, and intensity distribution based on the specific material and processing requirements, achieving high manufacturing precision through dynamic rather than static configuration
Solution Approach 2:
The system modifies key beam parameters including wavelength selection, focal length, beam diameter, and pulse duration to optimize processing outcomes for different materials. These parameter changes are controlled through integrated software that automatically selects optimal settings based on the workpiece material and desired operation
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 precise and efficient processing of materials with composite structures by adjusting beam characteristics to match the specific needs of each material, preventing damage and improving processing outcomes.
Implementation Method 1
an optical element arranged to separate the first composite beam into individual second laser beams
Implementation Method 2
arranged to combine the individual second laser beams, including at least one individual second laser beam with a modified wave front, into a second composite beam
Data Source
AI summary
Laser processing systems for processing one or more materials or combination of materials with composite laser energy and associated systems and methods are disclosed herein. In several embodiments, for example, a laser processing system includes one or more laser sources that provide a first plurality of first laser beams and preconditioning optics that combine the first laser beams into a first composite beam. The system also includes recomposition optics that separate the first composite beam into second plurality of second laser beams and combine the second laser beams into a second composite beam. The system further includes beam modification optics that modify wave fronts of one or more of the individual second laser beams such that the second composite beam has one or more beam characteristics that are modified relative to corresponding beam characteristics of the first composite beam. For example, the second laser beams of the second composite beam can focus at a common focusing plane.