Recycled Light Optics for Higher-Throughput Additive Manufacturing
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Solution Overview
Problem
In laser-based additive manufacturing systems, a significant amount of light is wasted due to the rejection of unwanted light patterns, leading to inefficiencies in throughput and energy utilization.
Innovation Solution
An optical system is developed to recycle and reuse rejected light by employing a pixel addressable light valve and image relays, allowing the recycling of energy through beam shaping optics and image relays to maintain high throughput rates and increase intensity for printing difficult materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask is applied to pattern the light using a liquid crystal light valve, then the light can be spatially modulated to build parts, but the unwanted polarized light is rejected and wasted
Solution Approach 1:
The patent converts the rejected unwanted polarized light, which was previously discarded as waste energy, into a useful resource by redirecting it through optical elements to combine with the original light beam, thereby increasing overall light intensity and reducing energy waste
Solution Approach 2:
Instead of discarding the rejected light at the beam dump, the system recovers this light by redirecting it through additional optical paths and combines it back with the main beam, effectively recovering energy that would otherwise be lost
2Ease of operation
If rejected light is discarded to a beam dump, then the polarization state separation is achieved, but the energy utilization efficiency decreases
Solution Approach 1:
The system transforms the previously harmful waste light into a beneficial resource by redirecting it through optical elements to augment the main light beam, thereby improving energy utilization while maintaining polarization separation functionality
Solution Approach 2:
The optical system achieves multi-functionality by simultaneously maintaining polarization state separation for precise light patterning while also recovering and recycling the rejected light to improve overall energy efficiency
3Productivity
If the light intensity is increased by recycling rejected light, then the print rate increases, but the system complexity increases
Solution Approach 1:
The patent introduces intermediary optical elements (additional mirrors, beam combining optics) that mediate between the light valve and the build platform, enabling light recycling functionality while maintaining a modular system architecture
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 recycling of rejected light increases the overall light intensity, enabling faster print rates and more efficient use of energy, thereby maintaining high printing rates and reducing energy costs.
Implementation Method 1
Liquid crystal based light valves allow for the spatial modulation of transmitted or reflected light by rotating the electromagnetic wave polarization state
Implementation Method 2
An optical system is developed to recycle and reuse rejected light by employing a pixel addressable light valve and image relays, allowing the recycling of energy through beam shaping optics and image relays
Data Source
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AI summary
A method and an apparatus pertaining to recycling and reuse of unwanted light in additive manufacturing can multiplex multiple beams of light including at least one or more beams of light from one or more light sources. The multiple beams of light may be reshaped and blended to provide a first beam of light. A spatial polarization pattern may be applied on the first beam of light to provide a second beam of light. Polarization states of the second beam of light may be split to reflect a third beam of light, which may be reshaped into a fourth beam of light. The fourth beam of light may be introduced as one of the multiple beams of light to result in a fifth beam of light.