Multi-Mode Laser Head for Wire-Powder Metal Processing
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Solution Overview
Problem
Existing laser-based manufacturing systems face limitations such as energy loss through optical fibers, potential for fiber breakage, inability to handle both wire and powder feed materials simultaneously, and lack of inert gas distribution, which restrict their application in additive manufacturing and other processes like welding, cutting, and texturing.
Innovation Solution
A compact multi-mode laser device that integrates multiple off-axis laser beams, independent power control, and simultaneous wire and powder feed capabilities, along with internal shield gas delivery, to provide a versatile solution for various metal manufacturing processes, including 3D metal printing and CNC machines.
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 processing head, but energy loss occurs and fibers are susceptible to breakage and damage from heat and reflection
Solution Approach 1:
The patent extracts the laser source from the processing head and places it externally, eliminating the need for optical fiber transmission through the head. The laser beam is delivered directly to the workpiece through a beam delivery system, removing the vulnerable optical fiber components from the high-heat, high-reflection environment at the processing head.
Solution Approach 2:
The patent introduces an intermediary beam delivery system (mirrors, lenses, beam guides) between the external laser source and the workpiece. This intermediary system transmits the laser energy without requiring optical fibers to pass through the processing head, thereby eliminating energy loss and fiber damage risks while maintaining power delivery capability.
2Device complexity
If a single laser head is used for multiple processes, then device complexity is reduced, but the system must accommodate multiple feed material types (wire and powder) which increases operational complexity
Solution Approach 1:
The patent designs a universal processing head that can handle multiple material feed types (wire and powder) and support multiple laser processes (welding, cladding, additive manufacturing). The head incorporates interchangeable or selectable feed mechanisms that allow operators to configure the system for different material types without requiring separate dedicated heads for each process.
Solution Approach 2:
The patent implements dynamic, reconfigurable feed material delivery systems within the single head. The wire feed mechanism and powder delivery system can be selectively activated or deactivated based on the required process, allowing flexible adaptation to different operational modes while maintaining a unified head structure.
3Device complexity
If inert gas distribution is not provided, then device complexity is reduced, but optical components are vulnerable to damage from laser reflection and heat
Solution Approach 1:
The patent incorporates an inert gas delivery system that supplies protective gas (such as nitrogen or argon) to the processing head and optical component areas. This inert atmosphere prevents oxidation of optical components, reduces the impact of laser-induced plasma formation, and protects against damage from high-energy reflection, thereby enhancing the reliability and lifespan of optical elements.
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 precise metal deposition and processing across multiple applications by minimizing energy loss, ensuring reliable operation, and accommodating both wire and powder feed materials, while protecting optical components and maintaining a controlled atmosphere.
Implementation Method 1
a plurality of off-axis laser light sources delivering laser light beams to a focal point on a work surface
Implementation Method 2
delivering laser light beams to a focal point on a work surface
Implementation Method 3
back-reflection protection through a photo-sensor to detect back-reflection and permit momentary deactivation
Implementation Method 4
capable of melting and processing metal wire and metal powder simultaneously
Implementation Method 5
delivering laser light beams to a focal point on a work surface
Data Source
Figure 1~2
Figure 3A~4B
Figure 5A~5B
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.