Photonic Lantern Array for Additive Manufacturing Laser Redundancy
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Solution Overview
Problem
Additive manufacturing systems face reliability issues due to single-point failures in laser energy sources, leading to reconfiguration, longer build times, and potential abandonment of builds, with existing solutions often resulting in unnecessary duplication of equipment and energy losses.
Innovation Solution
The implementation of photonic lanterns along energy paths to combine and redirect laser energy from multiple sources, creating redundant pathways with minimal energy loss, allowing for dynamic switching and feedback-controlled operation to maintain desired output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser energy sources are used to improve manufacturing capability, then productivity is improved, but reliability deteriorates due to increased risk of single-point failures
Solution Approach 1:
The patent segments the laser energy delivery system into multiple independent laser energy sources (e.g., five separate laser sources) that can operate independently. Each laser source can be independently controlled and failed without affecting the others, allowing the system to maintain functionality even when individual components fail.
Solution Approach 2:
The patent implements local quality by providing independent control and monitoring of each laser energy source. Each laser source has its own control mechanism and can be independently adjusted or isolated based on its performance state, allowing localized maintenance or replacement without shutting down the entire system.
2Reliability
If redundant laser energy sources are added to improve reliability, then system reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple laser energy sources into a unified system where the lasers are optically combined and delivered through a shared optical path and single toolhead assembly. This consolidation reduces the complexity that would otherwise result from having separate independent delivery systems for each laser source.
Solution Approach 2:
The patent creates a universal optical delivery system that can route energy from multiple laser sources through a common optical path. The system uses a single toolhead and optical assembly to handle energy from all laser sources, making the delivery mechanism multi-functional and reducing overall system complexity.
3Reliability
If conventional redundant systems are implemented, then reliability is improved, but energy loss increases due to unnecessary duplication
Solution Approach 1:
The patent combines multiple laser energy sources into a unified optical path where energy from all lasers is merged and delivered through a single optical assembly. This eliminates the need for separate optical paths and delivery mechanisms for each laser source, reducing energy losses that would occur in conventional duplicated systems.
Solution Approach 2:
The patent converts the potential harm of energy loss in redundant systems into a benefit by using the combined energy from multiple laser sources to create a more efficient single-pass manufacturing process. The merged energy delivery system reduces overall energy losses while maintaining the reliability benefits of having multiple laser sources.
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
Enhances the reliability and controllability of additive manufacturing by providing redundant energy paths with low loss, enabling rapid response to failures and maintaining consistent output, thus reducing downtime and improving part quality.
Implementation Method 1
Each photonic lantern of the plurality of photonic lanterns is configured to combine laser energy from at least two laser energy sources of the plurality of laser energy sources
Implementation Method 2
an optics assembly configured to direct laser energy from the plurality of photonic lanterns toward the build surface to form a corresponding plurality of laser energy pixels on the build surface
Data Source
AI summary
Fiber optic laser energy paths including photonic lanterns for use in additive manufacturing systems are disclosed. According to some embodiments, a plurality of photonic lanterns are configured to combine laser energy from a plurality of laser energy sources. According to other embodiments, a first plurality of photonic lanterns may combine laser energy from a plurality of laser energy sources and a second plurality of photonic lanterns may furcate the combined laser energy and direct the furcated laser energy to form a plurality of laser energy pixels on a build surface. Laser energy paths including photonic lanterns my provide enhanced control and redundancy within an additive manufacturing system. The disclosure may apply to laser paths for all types of additive manufacturing systems. Some disclosed embodiments are directed to powder bed fusion additive manufacturing systems including a plurality of laser power sources.