Partition Laser Assembly Using Vector Shapes and Optical Field Modulation
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Solution Overview
Problem
Existing laser micromachining technologies face challenges in achieving high precision and uniformity due to positioning accuracy and alignment issues during point-by-point processing, leading to uncertainties in fabricating complex structures.
Innovation Solution
A partition laser assembling system and method based on vector graphic structure and optical field modulation, which uses a laser, beam shaping-polarization modulation module, beam modulation module, and objective lens to generate and focus laser spots corresponding to basic shapes, enabling efficient and precise fabrication of complex patterns by decomposing them into basic shapes and processing them in a vector path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If point-by-point laser processing is used, then the laser can process the target structure, but the positioning accuracy and alignment jitter will affect the uniformity and surface smoothness of the fabricated structure
Solution Approach 1:
The patent segments the complex target structure into multiple basic shapes (circles, ellipses, lines, arcs, polygons) that can be processed independently. By dividing the structure into these fundamental geometric elements, the system can process each segment with optimized laser parameters, thereby improving overall manufacturing precision while reducing the cumulative effect of positioning errors
Solution Approach 2:
The patent transitions from traditional point-by-point processing to a higher-dimensional approach by using vector graphic structures and holographic phase maps. This allows the laser to process entire shapes or patterns in a single pass rather than moving point-by-point, effectively adding a dimensional aspect to the processing that eliminates alignment jitter and improves surface smoothness
2Productivity
If point-by-point processing is used, then the laser can fabricate the target structure, but the processing time will be extended
Solution Approach 1:
The patent performs preliminary action by pre-defining the target structure as a vector graphic and pre-calculating the decomposition into basic shapes with their corresponding holographic phase maps. This preparation work is done before the actual laser processing, allowing the laser to execute the processing in a highly efficient manner without real-time computation delays, thereby significantly improving productivity
Solution Approach 2:
The patent replaces the mechanical point-by-point scanning system with an optical field modulation system using spatial light modulators and holographic phase maps. This substitution allows parallel processing of multiple features simultaneously through optical field shaping, dramatically reducing processing time while maintaining or improving precision
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 approach significantly improves processing efficiency, precision, and smoothness by directly fabricating complex structures from basic shapes, reducing uncertainties associated with point-by-point processing and enabling the creation of high-quality, complex three-dimensional structures.
Implementation Method 1
the beam shaping-polarization modulation module is configured to perform shaping and polarization state modulation on the laser beam to generate a linearly-polarized and collimated laser beam
Implementation Method 2
the objective lens is configured to focus the laser spots of the basic shapes on the target structure
Data Source
AI summary
A partition laser assembling based on vector graphic structure and optical field modulation includes a laser, a beam shaping-polarization modulation module, a beam modulation module, and an objective lens. The basic shape, size, and position information of a target structure are obtained by analyzing vector graphic information, and a holographic phase map of a spatial light modulator is designed. The phase map is loaded through the spatial light modulator to carry out phase modulation, so as to directly generate laser spots corresponding to basic shapes on a pupil plane of an objective lens. Then basic structures are automatically assembled on a material, realizing planar fabrication of complex structures. In combination with layer-by-layer fabrication technology, the three-dimensional fabrication of the complex structures is realized.