Optical Fiber Module Alignment Without Adhesive Under Heat
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Solution Overview
Problem
Additive manufacturing systems face challenges in accurately aligning optical fibers relative to downstream optics due to adhesive degradation from heat, leading to misalignment and contamination, which affects manufacturing efficiency and system functionality.
Innovation Solution
Employing mechanical fixtures, such as resilient members and stray light baffles, to maintain the position and alignment of optical fibers, while redirecting stray light and managing heat to prevent misalignment and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adhesive is used to position optical fibers, then initial alignment is achieved, but heat causes adhesive degradation leading to misalignment and contamination
Solution Approach 1:
The patent removes the adhesive from the optical fiber positioning system entirely. Instead of using adhesive to bond the optical fiber to the holder, a resilient member is introduced that mechanically positions the optical fiber without requiring adhesive bonding, thereby eliminating the source of heat-related degradation and contamination.
Solution Approach 2:
A resilient member is introduced as an intermediary component between the holder and the optical fiber. This resilient member mechanically positions and secures the optical fiber in the correct alignment without requiring adhesive, providing a heat-resistant solution that maintains alignment stability under thermal conditions.
2Productivity
If multiple laser energy sources are added to increase fusion rate, then manufacturing throughput improves, but system complexity and heat management challenges increase
Solution Approach 1:
The patent segments the optical fiber delivery system into modular units, each with its own resilient member and holder configuration. This segmentation allows multiple laser energy sources to be independently managed and positioned, reducing the overall system complexity while enabling increased manufacturing throughput through parallel processing.
3Manufacturing precision
If optical fibers are tightly constrained to maintain alignment, then registration accuracy improves, but heat-induced stress and potential damage increase
Solution Approach 1:
The patent employs a resilient member that provides flexible mechanical constraint to the optical fiber. This resilient member maintains the optical fiber in the correct registered position while allowing sufficient compliance to accommodate thermal expansion and contraction, thereby maintaining registration accuracy without imposing excessive constraining stress that could damage the optical fiber.
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
Improves registration and alignment of optical fibers, reduces heat-related stress, and minimizes contamination, enhancing manufacturing efficiency and system reliability.
Implementation Method 1
a resilient member configured to bias at least a portion of the at least one optical fiber towards the holder
Implementation Method 2
the at least one stray light baffle comprising at least one tapered surface configured to redirect at least a portion of stray laser energy directed toward the at least one laser energy source
Data Source
AI summary
Systems and methods for additive manufacturing are generally described. In some embodiments, an additive manufacturing system may include at least one mechanical fixture in the form of a resilient member for accurately positioning one or more optical fibers without the use of adhesives. The resilient member may, in some embodiments, bias each optical fiber (or similarly, an endcap coupled to a distal end of an optical fiber) against an alignment fixture to maintain a desired position and/or orientation of the fiber or endcap. In some embodiments, an additive manufacturing system may include at least one stray light baffle for reducing the amount of stray light within the optical system.