Optical Beam Correction for Heated-Air Laser Manufacturing
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Solution Overview
Problem
Laser-based manufacturing processes face challenges due to atmospheric distortions caused by localized heating, leading to beam defocusing and reduced energy delivery at target locations, which can result in inefficient processing and increased manufacturing time.
Innovation Solution
An optical correction system pre-distorts the laser beam to counteract atmospheric distortions by applying a conjugate phase-front shape, allowing the beam to maintain focus and energy delivery even through distorted regions, thereby enabling faster and more efficient manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser beam is directed through heated atmospheric region, then material processing is achieved, but beam defocusing occurs due to refractive index variations
Solution Approach 1:
The patent applies preliminary anti-action by pre-distorting the laser beam wavefront in advance before it enters the heated atmospheric region. The optical system introduces a conjugate phase distortion that anticipates and counteracts the refractive index variations the beam will encounter, thereby maintaining focus precision and energy delivery reliability throughout the beam path.
Solution Approach 2:
The patent implements preliminary action by measuring and characterizing the atmospheric distortion region in advance using a probe beam, then using this information to pre-correct the main laser beam's wavefront. This preliminary characterization allows the system to prepare the appropriate optical correction before the processing beam enters the distorted region.
2Power
If laser power is increased to compensate for energy loss, then processing effectiveness is maintained, but atmospheric distortion is worsened
Solution Approach 1:
The patent employs feedback by using a probe beam to continuously monitor the atmospheric distortion region and feed this information back to the optical correction system. This real-time feedback allows the system to dynamically adjust the wavefront correction to maintain optimal beam focus without increasing power, thereby avoiding additional atmospheric heating and distortion.
3Manufacturing precision
If beam path is retargeted to avoid distorted regions, then focus is maintained, but manufacturing time increases
Solution Approach 1:
The patent introduces an intermediary optical correction system that acts as a mediator between the laser beam and the distorted atmospheric region. Rather than avoiding the distorted region or increasing power, the optical system (including wavefront sensors and corrective optics) serves as an intermediary that actively manages and corrects the beam's interaction with the heated atmosphere, maintaining both precision and productivity.
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
The optical correction system enhances the precision and throughput of laser-based manufacturing by reducing the need for retargeting and power increases, while minimizing delays between process steps and improving spot size and phase-front performance.
Implementation Method 1
The optical system is configured to pre-distort a beam of light to account for atmospheric distortion along a path between a laser device and a target location on a material used in the manufacturing operation. The atmospheric distortions can cause phase-front shape changes in a beam of light directed along the path
Implementation Method 2
The localized heating can result in significant temperature differences along the path that the beam of light traverses between the laser device and the material. Such temperature differences (or associated density differences) can cause a refractive index of the atmosphere to vary along the path that the beam of light traverses
Data Source
Figure 1
Figure 2~3
Figure 4A~4C
AI summary
A method of forming an object from a material includes directing a first beam of light toward a first target location of the material to define a first portion of the object. The method also includes, after directing the first beam of light toward the first target location, determining an optical correction to be applied by an optical system. The optical correction is based on an atmospheric change in an atmospheric distortion region proximate the first target location due, at least in part, to interaction of the first beam of light and the material. The method further includes directing a second beam of light toward a second target location of the material to define a second portion of the object. The second beam of light is directed through at least a portion of the atmospheric distortion region while the optical correction is applied.