Phase-Patterned Laser Printing for Beam Steering and Multi-Layer Fusion
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Solution Overview
Problem
Current additive manufacturing systems using high power lasers face limitations in efficiently applying patterned high energy beams for complex printing tasks, such as simultaneous multi-layer printing and precise beam steering, which affects the control and quality of printed patterns and materials like metal/ceramic powders.
Innovation Solution
The use of phase patterning units and holographic light valves to generate and manipulate high fluence beams, allowing for phase modification, beam redirection, and simultaneous multi-layer printing by combining beams with controlled phase delays, and incorporating phased array lambda magic mirrors for non-mechanical beam steering and gray scale modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional high power laser systems are used for additive manufacturing, then basic printing functionality is achieved, but control over beam patterns and directionality is insufficient for complex printing tasks
Solution Approach 1:
A phase patterning unit is introduced as an intermediary component between the laser source and the powder bed. This unit modulates the phase of the laser beam to create precise beam patterns and control directionality, enabling complex printing tasks such as simultaneous multi-layer printing and volumetric printing without requiring multiple laser sources or complex mechanical steering systems.
Solution Approach 2:
The patent replaces mechanical beam steering systems with a phase-based optical control approach. Instead of using moving mirrors or galvanometers to redirect the beam, the system uses phase modulation to electronically control beam direction and pattern, eliminating mechanical complexity while improving precision and enabling simultaneous multi-point printing.
2Productivity
If high fluence beams are used for additive manufacturing, then printing speed and layer fusing quality are improved, but beam steering and pattern control become difficult
Solution Approach 1:
The phase patterning unit dynamically adjusts the phase of different portions of the laser beam independently and rapidly. This dynamic phase control allows the system to steer high fluence beams precisely to different locations and create complex patterns on the powder bed without mechanical movement, enabling both high printing speed and precise beam control simultaneously.
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 enables precise control over beam patterns and directionality, allowing for improved layer fusing, volumetric printing, and efficient manipulation of heavy powders, enhancing the overall quality and versatility of additive manufacturing processes.
Implementation Method 1
A phase patterning unit is used to receive and alter phase of a beam from at least one of the two high power lasers
Implementation Method 2
use of holographic techniques for application of high fluence beams
Implementation Method 3
at least two high power, mutually coherent lasers to generate beams
Implementation Method 4
The merged beams are directly mixed at the bed to provide printed patterns
Data Source
AI summary
An additive manufacturing system includes at least two high power lasers to generate beams. A phase patterning unit is used to receive and alter phase of a beam from at least one of the two high power lasers. At least one phase patterned beam can be mixed with another beam at a print the print bed. In some embodiments, beams are moved with respect to the print bed by changes in phase patterns from the phase patterning unit. In other embodiments, phase patterns from the phase patterning unit can be used for simultaneous printing of multiple layers.