Multi-Core Optical Fiber Exposure for Faster 3D Printing
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Solution Overview
Problem
Existing exposure devices for additive manufacturing of three-dimensional objects face challenges in improving component and process quality, efficiency, and productivity, particularly in the configuration of optical fibers used to conduct energy beams.
Innovation Solution
The exposure device incorporates a multi-core optical fiber with separate fiber cores that can be optically coupled to energy beam generating devices, allowing for the generation and control of multiple energy beams with varying parameters, enabling targeted energy radiation profiles and increased construction rates through direct or indirect coupling methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single optical fiber is used to conduct energy beams, then the device structure is simple, but the construction rate and productivity are limited
Solution Approach 1:
The optical fiber is divided into multiple independent fiber cores (at least two fiber cores) within a single fiber structure. Each fiber core can independently conduct energy beams, enabling parallel processing of multiple building material areas simultaneously. This segmentation increases the construction rate by allowing concurrent exposure of different regions while maintaining the compactness of a single fiber connection.
Solution Approach 2:
The multi-core optical fiber serves multiple functions: each fiber core can independently deliver energy beams to different areas of the build plate, enabling simultaneous multi-location exposure. The single fiber structure replaces what would traditionally require multiple separate fiber connections, simplifying the overall system while providing enhanced functionality through parallel beam delivery.
2Productivity
If multiple energy beams are conducted through separate optical fibers, then the construction rate increases, but the device complexity and space requirements increase
Solution Approach 1:
Multiple fiber cores are nested within a single optical fiber structure. This nested configuration allows multiple energy beam transmission channels to occupy the same physical space, reducing the overall footprint and coupling area required compared to using separate fibers for each beam. The fiber cores are spatially arranged within the single fiber to enable independent beam delivery while minimizing external space requirements.
3Adaptability or versatility
If a multi-core optical fiber is used, then variable energy beam profiles and thermal treatments are enabled, but the manufacturing complexity increases
Solution Approach 1:
Different fiber cores within the optical fiber can be designed with different properties (core diameters, numerical apertures, transmission wavelengths) to deliver energy beams with specific characteristics tailored to different processing requirements. This local differentiation enables variable energy beam profiles and specialized thermal treatments for different areas of the build plate while using a standardized multi-core fiber structure.
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 enhances component and process quality, efficiency, and productivity by allowing for variable energy beam profiles and higher construction rates, enabling precise thermal pre- and post-treatments of building material layers.
Implementation Method 1
The optical fiber is designed to conduct at least one energy beam coupled into it between a coupling-in area of the optical fiber and a coupling-out area of the optical fiber
Implementation Method 2
The energy beam generating device is set up to generate an energy beam, the optical fiber is set up to conduct at least one energy beam coupled into it
Data Source
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AI summary
Exposure device (6) for a device (1) for the additive manufacturing of three-dimensional objects (2), comprising: - at least one energy beam generating device (7) which is configured to generate an energy beam (4), - at least one optically coupled or coupled optical fiber (8) to the energy beam generating device (7), which is configured to guide at least one energy beam (4) coupled into it between an input coupling area (8a) of the optical fiber (8) and an output coupling area (8b) of the optical fiber (8), wherein the optical fiber (8) comprises several fiber cores (15), wherein at least one energy beam (4) can be coupled into or is coupled into each fiber core (15).