Optical Fiber Connector Assembly for Replaceable Multi-Laser AM
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Solution Overview
Problem
Additive manufacturing systems, particularly powder bed fusion systems, face limitations in manufacturing speed and throughput due to the rate of material fusion, which is constrained by laser power and the reliability of multiple laser energy sources, and existing optical fiber connectors are not well-suited for high-power applications, leading to inefficiencies and difficulties in component replacement.
Innovation Solution
The system incorporates a plurality of laser energy sources with an optics assembly and optical fiber connectors that allow for easy replacement of components without disrupting the manufacturing process, using a configuration where optical fibers are grouped into cables with alignment fixtures for efficient alignment and a movable optics assembly to reduce stress on optical fibers, and employs fusion splices for efficient power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser energy sources are used to increase manufacturing speed, then productivity increases, but system complexity and reliability challenges increase
Solution Approach 1:
The system divides the laser delivery function into multiple independent laser energy sources, each coupled to the optics assembly through separate optical fibers. This segmentation allows parallel operation of multiple lasers to increase manufacturing speed while maintaining independent failure modes that simplify troubleshooting and replacement.
Solution Approach 2:
The optical fiber connector assembly serves multiple functions: it couples multiple laser energy sources to the optics assembly, provides alignment fixtures for precise positioning, enables rapid replacement of failed components, and maintains the inert gas environment. This multi-functionality reduces overall system complexity despite using multiple lasers.
2Loss of energy
If optical fiber connectors are used for high-power laser transmission, then power transmission efficiency improves, but heating issues and reliability problems worsen
Solution Approach 1:
The optical fiber connector assembly acts as an intermediary component between the laser energy sources and the optics assembly. It provides a controlled environment for high-power laser transmission with proper alignment and coupling, minimizing energy loss while managing heat generation through its design that allows for efficient power transmission.
Solution Approach 2:
The connector assembly maintains an inert gas environment within the build volume, protecting the optical fibers and connectors from oxidation and contamination at high temperatures. This inert atmosphere prevents harmful chemical reactions that could exacerbate heating issues and improves reliability of the optical components.
3Ease of repair
If optical fibers are made replaceable for maintenance, then ease of repair improves, but connection reliability and alignment precision worsen
Solution Approach 1:
The alignment fixtures are pre-configured in the connector assembly to provide precise alignment positions for the optical fibers. This preliminary preparation ensures that when fibers are replaced, they can be quickly connected with proper alignment, maintaining connection reliability while enabling easy repair. The fixtures are designed beforehand to guide the replacement process.
Solution Approach 2:
The system replaces complex mechanical alignment mechanisms with pre-configured alignment fixtures that provide precise positioning through their structure alone. This substitution simplifies the replacement process (improving ease of repair) while maintaining alignment precision (preserving connection reliability) by eliminating the need for complex adjustment mechanisms during replacement.
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
This configuration increases manufacturing speed and reliability by allowing for rapid replacement of failed components without interrupting the process, reduces downtime, and maintains the inert gas environment within the build volume, while optimizing power transmission efficiency and minimizing heating issues.
Implementation Method 1
a first plurality of optical fibers extending between the plurality of laser energy sources and the optical fiber connector... a second plurality of optical fibers extending between the optical fiber connector and the optics assembly
Implementation Method 2
employs fusion splices for efficient power transmission
Data Source
AI summary
Disclosed embodiments relate to additive manufacturing systems. In some embodiments, an additive manufacturing system may include a plurality of laser energy sources, an optics assembly configured to direct laser energy onto a build surface, and an optical fiber connector positioned between the plurality of laser energy sources and the optics assembly. A first plurality of optical fibers may extend between the plurality of laser energy sources and the optical fiber connector, and a second plurality of optical fibers may extend between the optical fiber connector and the optics assembly. Each optical fiber of the first plurality of optical fibers may be coupled to a corresponding optical fiber of the second plurality of optical fibers within the optical fiber connector.