Pulse Laser 3D Printing With Grid Voids for High-Speed Precision
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Solution Overview
Problem
Current laser 3D printing processes are limited by slow speeds and high costs, with a trade-off between precision and speed, particularly when printing large parts, as existing methods either sacrifice detail for speed or precision for accuracy.
Innovation Solution
A pulse lasing apparatus controlled by a computing device that sends packets of instructions to form 3D prints and voids in a grid pattern, allowing for high-speed and high-precision printing by varying the pulse emission across a series of parallel rows with adjustable X and Y distances and offset configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If raster laser 3D printing processes are used to print row by row with individually gated pulses, then precision and resolution are improved, but speed is worsened due to the 100 kHz repetition rate limit and 10 μs update rate
Solution Approach 1:
The patent segments the image into multiple bands or zones that can be processed simultaneously. Instead of printing row by row sequentially, the laser beam is divided into multiple parallel scan lines that operate in parallel, effectively multiplying the processing throughput while maintaining the precision of individual pulse placement.
Solution Approach 2:
The patent transitions from one-dimensional sequential row processing to two-dimensional parallel band processing. By organizing the print area into multiple horizontal bands that can be processed simultaneously, the system adds a spatial dimension to the processing architecture, enabling parallel execution without sacrificing the precision of individual pulse placement.
2Productivity
If vector 3D printing processes are run above 100 kHz with steered laser beams, then speed is improved, but placement accuracy is worsened at very high surface velocities
Solution Approach 1:
The patent implements dynamic adjustment of laser parameters based on real-time beam position and velocity. The system continuously adapts pulse timing, energy, and positioning compensation to maintain accuracy across varying scan speeds, allowing high-speed operation without sacrificing placement precision.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor laser beam position and velocity, then adjust subsequent pulse placement accordingly. This closed-loop control enables the system to compensate for high-speed effects and maintain accurate placement even at velocities that would normally degrade precision.
3Productivity
If pulse spacing is increased to make raster printing faster, then speed is improved, but fine detail is sacrificed
Solution Approach 1:
By segmenting the image into multiple bands and processing them in parallel, the system can use larger pulse spacing within each band while still achieving fine overall detail through the combined resolution of multiple bands. The segmentation allows speed optimization at the band level without sacrificing detail at the pixel level.
Solution Approach 2:
The patent uses the spatial arrangement of multiple parallel bands to compensate for increased pulse spacing. By distributing features across multiple bands rather than relying solely on dense pulsing within a single row, the system maintains fine detail resolution while operating at higher speeds with larger pulse intervals.
4Adaptability or versatility
If lasers are operated at higher energies and wavelengths, then versatility is improved, but process cost is worsened
Solution Approach 1:
The patent implements a multi-functional laser system that can operate across multiple wavelengths and energy levels to process different materials and achieve different effects. The system is designed to be universally applicable to various materials (polymers, metals, ceramics) and processing modes (melting, sintering, photopolymerization), reducing the need for specialized equipment for each material type.
Solution Approach 2:
The system dynamically adjusts laser parameters including wavelength, pulse duration, and energy level based on the specific material and desired outcome. This parameter optimization allows the use of higher energy lasers only when necessary, reducing overall process cost while maintaining versatility across different materials and applications.
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
Enables faster and more precise 3D printing with improved accuracy and reduced cycle times, capable of producing complex designs and consumer-readable features without the need for specialized tools, while maintaining cost-effectiveness.
Implementation Method 1
A pulse lasing apparatus is used to form a plurality of 3D prints on a part
Implementation Method 2
Another laser technique known as stereolithography (SLA) uses shorter wavelength lasers to locally photopolymerize a liquid
Data Source
AI summary
A part 3D printed by a pulse lasing apparatus. The part has a predetermined feature comprising a plurality of 3D prints and voids in a grid pattern. The grid pattern has a plurality of locations disposed along a series of substantially parallel rows, and each location comprises either one 3D print or one void. The pulses from the pulse lasing apparatus form the 3D prints and the absence of a pulse forms the voids. The pulse lasing apparatus is controlled by a computing device that sends packets of instructions to the pulse lasing apparatus, the packet of instructions comprising at least 2, where each individual instruction informs the laser to pulse or not to pulse, creating a 3D print or a void, respectively, at each location on the grid pattern.