Multi-Stage Optical Zoom for Independent Laser Spot Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing systems lack the ability to independently control the size and spacing of laser beam spots on a build surface, limiting the complexity and variety of materials that can be processed.
Innovation Solution
The system includes a multi-stage optics assembly with micro and macro optics subassemblies, allowing for independent control of laser beam spot size and spacing through adjustable lens arrays and lenses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional single-stage optics are used, then the system is simple, but the ability to independently control laser spot size and spacing is limited
Solution Approach 1:
The optics system is divided into two independent stages: a first stage with a first lens array that controls laser spot size, and a second stage with a second lens array that controls laser spot spacing. This segmentation allows each stage to independently adjust one parameter without affecting the other, enabling versatile control of both spot size and spacing simultaneously.
2Adaptability or versatility
If fixed optics configuration is used, then the system is easy to manufacture, but it cannot process complex geometries and multi-materials
Solution Approach 1:
The lens arrays in both stages are made adjustable rather than fixed. The first lens array can be repositioned to change spot size, and the second lens array can be repositioned to change spot spacing. This dynamic adjustability allows the system to adapt to different material properties and geometry complexities, enabling processing of diverse materials and complex structures.
3Manufacturing precision
If coupled control of spot size and spacing is used, then the optics system is simpler, but independent control of each parameter is lost
Solution Approach 1:
The control of spot size and spacing is segmented into two independent functions: the first lens array exclusively controls spot size through its positioning, while the second lens array exclusively controls spot spacing through its positioning. This functional segmentation eliminates coupling between the parameters, allowing precise independent control of both spot size and spacing.
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 enables greater control over the printing process, allowing for the fabrication of complex geometries and the processing of non-homogeneous and multi-materials, while also accommodating a wide range of input laser powers and scaling to large arrays of lasers.
Implementation Method 1
a plurality of lens arrays configured to adjust a size of each of the plurality of laser spots on the build surface
Implementation Method 2
at least one lens configured to adjust a spacing between the plurality of laser spots on the build surface
Implementation Method 3
a plurality of laser energy sources configured to produce a plurality of lasers to form a plurality of laser spots on the build surface
Data Source
AI summary
Optics assemblies and their methods of use in additive manufacturing systems are described. In some embodiments, an additive manufacturing system may include a build surface, a plurality of laser energy sources configured to produce a plurality of laser spots on the build surface, and an optics assembly configured to independently control a size of each of the plurality of laser spots and a spacing between the plurality of laser spots on the build surface. The optics assembly may include a plurality of lens arrays, where the plurality of lens arrays is configured to adjust a size of each of the plurality of laser spots on the build surface, and at least one lens. The at least one lens may also be configured to adjust a spacing between the plurality of laser spots on the build surface.