Multi-Mode Laser Head for Wire-Powder Metal Deposition
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Solution Overview
Problem
Existing laser-based manufacturing systems face limitations such as energy loss, fiber breakage, and incompatibility with wire and powder feed materials, as well as lack of inert gas distribution and reflection protection, restricting their application in additive manufacturing, welding, cutting, and texturing processes.
Innovation Solution
A compact multi-mode laser device that integrates multiple fiber-coupled diode lasers, allowing for simultaneous wire and powder deposition, inline process controls, and shield gas delivery through a single device, with off-axis laser beams and precision monitoring to optimize deposition and protect optical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If external lasers with optical fiber transmission are used, then laser power can be delivered to the head, but energy loss occurs and fiber breakage and connector damage may happen due to heat, mechanical interactions, and reflection
Solution Approach 1:
The patent extracts the laser source from external location and integrates it directly into the deposition head, eliminating the optical fiber transmission path. This removes the source of energy loss, fiber breakage, and connector damage while maintaining full laser power delivery capability for metal deposition processes
Solution Approach 2:
The patent combines multiple previously separate components (laser source, deposition head, powder feed system, wire feed system, inert gas distribution) into a single integrated multi-mode device. This merging eliminates energy loss at interfaces and improves reliability by removing vulnerable connection points
2Adaptability or versatility
If a single laser device is used for multiple applications, then versatility is improved, but device complexity increases
Solution Approach 1:
The patent designs a universal deposition head that can perform multiple metal manufacturing processes (additive manufacturing, cladding, welding, cutting, texturing, polishing) using a single integrated device. The system achieves versatility through configurable laser parameters and multiple material feed options rather than increasing physical complexity
Solution Approach 2:
The patent employs dynamic control of laser parameters (power, focal position, scan speed) and material feed rates to adapt the single device for different applications. This dynamic adjustment capability allows one device to replace multiple specialized devices without proportionally increasing complexity
3Ease of operation
If fiber-coupled lasers are used, then laser delivery is achieved, but fiber breakage and connector damage occur from heat, mechanical interactions, and reflection
Solution Approach 1:
The patent removes the optical fiber from the system by integrating the laser source directly into the deposition head. This extraction eliminates the vulnerable fiber transmission path while maintaining ease of laser delivery through direct coupling to the working optics
Solution Approach 2:
The patent converts the harmful effects (heat, reflection, mechanical stress) that damage optical fibers into benefits by eliminating the fiber entirely. The same physical phenomena are managed more effectively through direct laser-to-workpiece coupling without intermediate fiber transmission
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
Enables efficient and versatile metal manufacturing across various applications, including 3D printing and CNC machines, by providing high-effective laser power, precise control, and protection against reflection, while supporting both wire and powder feed materials and inert gas distribution.
Implementation Method 1
focus multiple laser beams onto a working surface where the laser focal point intersects with metal feed material
Implementation Method 2
laser light source to focus multiple laser beams
Implementation Method 3
laser focal point intersects with metal feed material (wire and/or powder) to form a metal layered construct
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
Disclosed is a multi-mode laser device for metal manufacturing applications including additive manufacturing (AM), laser cladding, laser welding, laser cutting, laser texturing and laser polishing. The multi-mode laser device configures off-axis, solid-state diode or diode-pumped lasers into an array to perform precision controlled, direct metal deposition printing, cladding, laser welding, laser cutting, laser texturing and laser polishing through a single device. Dual-mode printing, cladding and welding capability using metal wire and powder feedstock sources in the same device is provided with in-line control, precision wire feed driver/controller, adjustable shield gas diffuser, and nozzles tailored to wire feedstock diameter.