Optical Carriage Beam Shaping for Adjustable Laser Power Density
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Solution Overview
Problem
Conventional laser processing systems often employ a single laser beam that is not ideally suited for processing compositions of materials, as it may damage certain materials within the composition while being ineffective for others, lacking the ability to adjust power density and beam characteristics accordingly.
Innovation Solution
A laser processing system with a beam delivery subsystem and optical carriage assembly that modifies and focuses a laser beam to achieve adjustable power density, using a power density optics unit to provide discrete or infinitely variable expansion or contraction of the beam, allowing for tailored processing of various materials and compositions by controlling beam characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single laser beam is used for processing material compositions, then the system structure is simple, but it cannot process different materials with different power density requirements simultaneously
Solution Approach 1:
The patent divides the single laser beam into multiple separate beams using beam splitting optics. Each beam can be independently directed to different material zones with specific power density requirements, enabling simultaneous processing of heterogeneous materials while maintaining a relatively simple overall system architecture
Solution Approach 2:
The patent employs dynamic beam control mechanisms including movable mirrors and adjustable beam shaping optics that can real-time modify beam characteristics (power density, focal position, beam shape) to adapt to different material processing requirements, providing versatility without requiring multiple fixed laser sources
2Manufacturing precision
If beam expansion or contraction optics are added to adjust power density, then material processing precision is improved, but the optical system complexity increases
Solution Approach 1:
The patent designs optical components that perform multiple functions: beam splitting optics also serve as beam shaping elements, and focusing mirrors simultaneously handle multiple beams with different power density requirements. This multi-functionality reduces the total number of components needed, improving precision while limiting complexity increase
Solution Approach 2:
The patent implements a nested optical configuration where beam expansion/contraction optics are integrated within the existing focusing optical train. The beam shaping elements are positioned at intermediate focal points rather than adding separate external optical trains, allowing compact integration that minimizes system complexity while achieving precise power density control
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 precise and accurate processing of diverse materials and compositions by optimizing power density and beam characteristics, improving cutting accuracy and repeatability without requiring changes to the final focus lens or working distance, thus overcoming the limitations of single-beam systems.
Implementation Method 1
a power density optics unit configured to provide discrete or infinitely variable expansion or contraction of the laser beam
Implementation Method 2
focusing the modified laser beam within a material processing field to obtain an adjustable power density within a material processing plane
Data Source
AI summary
Systems and methods for laser processing systems and associated methods for using and manufacturing such systems are disclosed herein. In some embodiments, a laser processing system includes a controller, a laser source, a material support, and a beam delivery subsystem operably coupled to the controller. The beam delivery subsystem comprises an optical carriage assembly configured to receive and modify a laser beam from the laser source, and direct the laser beam toward a material to be processed carried by the material support. The optical carriage assembly is further configured to focus the laser beam within a material processing field to obtain an adjustable power density within a material processing plane and achieve an optimal selected condition for the material to be processed.