Additive Manufacturing Print Head with Digital Micromirror Device
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Solution Overview
Problem
Additive manufacturing apparatuses face challenges with expensive and difficult-to-align scanner assemblies that generate heat and soot, limiting the consolidation rate of build materials.
Innovation Solution
A self-contained print head that utilizes multiple laser beams to fuse powdered build materials, featuring a housing with a beam emitter, projection element, and consolidating optic, which is more energy-efficient, cost-effective, and scalable, reducing soot generation and allowing modular expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional scanner assemblies are used to focus and scan laser beams, then the build material can be melted or fused, but the equipment becomes expensive and difficult to align and maintain
Solution Approach 1:
The patent extracts the scanning function from the laser source by using a separate digital micromirror device (DMD) to deflect the laser beams. This separation allows the laser generator to be a simple fiber laser without complex scanning mechanisms, while the DMD handles all scanning and steering functions digitally, eliminating mechanical alignment issues.
Solution Approach 2:
The patent replaces mechanical scanner assemblies with a digital micromirror device that uses electronically controlled mirror tilting to deflect laser beams. This substitution eliminates mechanical moving parts, alignment drift, and maintenance requirements associated with traditional galvanometer scanners.
2Productivity
If additional scanner assemblies are added to increase consolidation rates, then more build material can be processed, but heat loads and soot generation increase
Solution Approach 1:
The patent uses a digital micromirror device with thousands of individually controllable mirrors to create multiple laser beams that can be positioned anywhere in the build area simultaneously. This transforms the scanning approach from sequential mechanical movement to parallel optical positioning, enabling high consolidation rates without additional physical scanners.
Solution Approach 2:
The patent changes the operational parameters by using pulsed laser delivery synchronized with the DMD mirror switching. This allows precise control of laser-on-time and energy delivery, melting only the necessary powder with minimal excess heating and soot generation, while achieving high consolidation rates through rapid sequential pulsing.
3Ease of operation
If traditional scanner assemblies are used, then laser beams can be scanned over the build plane, but the equipment becomes expensive and requires difficult maintenance
Solution Approach 1:
The patent makes the DMD serve multiple functions: it acts as a scanning mirror, a beam steering device, a focus control mechanism, and a pattern projection system all in one component. This multi-functionality eliminates the need for separate mechanical scanners, alignment mechanisms, and focus assemblies, dramatically reducing cost and simplifying operation.
Solution Approach 2:
The DMD is a solid-state device with no moving parts that requires no alignment or calibration once installed. It is driven entirely by digital signals from the control system, making it self-contained and eliminating the need for operator intervention for alignment or maintenance.
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
The solution enhances energy efficiency, reduces soot production, and allows for scalable expansion of build areas and part sizes in additive manufacturing, improving consolidation rates and manufacturing capabilities.
Implementation Method 1
focus and scan a laser beam over a build plane and melt or fuse the build material at the build plane
Implementation Method 2
melt or fuse the build material at the build plane
Data Source
AI summary
Disclosed herein are print heads for an additive manufacturing apparatus. The print heads include a housing. A projection element is disposed within the housing and is configured to receive the one or more laser beams generated by a beam emitter and project a plurality of projected laser beams in a pattern. A consolidating optic is disposed within the housing and is located below the projection element. The consolidating optic is configured to consolidate the pattern of the plurality of projected laser beams into a consolidated pattern of projected laser beams.