Radial Multi-Beam Laser Head for Omnidirectional Wire Feed
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Solution Overview
Problem
High power laser additive manufacturing systems face limitations in omnidirectional processing due to traditional wire feed mechanisms that obstruct the laser beam with off-axis consumable fill material, restricting tool travel directions and requiring complex beam splitting techniques that compromise power delivery and beam quality.
Innovation Solution
A multiple optical fiber core array is used to deliver multiple laser beams as a radial array surrounding a central tool axis, allowing spatial separation and focusing of beams for processing spots near the work surface, while enabling axial material feed along the central axis, facilitating omnidirectional processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional off-axis wire feed mechanism is used, then material can be delivered to workpiece, but laser beam is obstructed and tool travel directions are restricted
Solution Approach 1:
The laser beam is divided into multiple separate beams using beam splitting optics, with each beam independently focused to different locations around the central axis. This segmentation allows the fill material to be positioned centrally without obstructing any single beam path, enabling omnidirectional processing capability.
Solution Approach 2:
The system transitions from a single on-axis or off-axis beam configuration to a multi-dimensional array of beams arranged in radial patterns. By distributing beams across multiple spatial dimensions and angles, the system eliminates the need for complex mechanical beam steering while achieving omnidirectional processing coverage.
2Adaptability or versatility
If beam splitting techniques are used to accommodate central fill material, then omnidirectional processing is enabled, but power delivery and beam quality are compromised
Solution Approach 1:
Multiple copies of the original laser beam are created through the beam splitting system, with each copied beam maintaining the essential characteristics of the source beam. This allows adequate power delivery to be distributed across multiple focal points rather than concentrated in a single beam, preserving beam quality while enabling flexible processing directions.
3Area of stationary object
If continuous annular illumination is used, then complete area coverage is achieved, but feed material introduction is blocked
Solution Approach 1:
The continuous annular illumination is segmented into discrete radial beam positions, creating gaps in the illumination pattern. These gaps correspond to the central region where fill material can be introduced and positioned, allowing both complete area coverage through multiple beams and unobstructed material feed access.
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 solution provides flexible and efficient high power laser processing capabilities with simplified beam delivery, enabling omnidirectional processing and improved material addition to workpieces without obstructing the laser beam, enhancing processing speed and versatility.
Implementation Method 1
An optical system spatially separates the multiple beams into a processing output array of multiple processing beams arranged in a radial pattern surrounding a central tool axis and focuses each beam to a processing spot on a work surface
Implementation Method 2
irradiating one or more of the work surface and the wire with the processing spots and melting the filler material at the work surface such that material from the wire is added to the workpiece
Data Source
AI summary
Laser processing systems and methods image a multiple core array to a work surface in a multiple processing beam array. An optical system separates processing beams and converges the beams toward the work surface and focuses each beam of the array at or near the work surface. A central axis with access for filler material flow to the work surface is provided. The processing beam array and central filler material feed provide omni-directional additive laser processing capability.