Sealed Optical Module for Dust-Stable Laser Beam Alignment
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Solution Overview
Problem
Existing additive manufacturing apparatuses using laser beams face challenges in maintaining the accuracy and precision of sensitive optics, which are difficult to set up and repair in dusty environments, leading to performance deterioration and increased downtime.
Innovation Solution
A removably mountable optical module with a hermetically sealable housing containing focusing and steering components, allowing precise alignment and testing in a clean environment, and equipped with monitoring tools and cooling systems to maintain a controlled atmosphere and prevent dust and humidity ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sensitive optical components are built into the chassis of the manufacturing apparatus, then the laser beam can be controlled with high accuracy, but the optics become difficult to set up and repair in dusty environments
Solution Approach 1:
The optical system is divided into a separate removably-mountable module that can be detached from the main apparatus chassis. This module contains all sensitive optical components (focusing optics, scanners, lenses) as a self-contained unit, allowing it to be prepared and aligned in a clean environment then removed for repair or replacement without disassembling the entire apparatus.
Solution Approach 2:
The sensitive optical components are extracted from the dusty manufacturing apparatus environment and placed into a separate hermetically sealable module. This extracted module can be set up and maintained in controlled clean conditions, then mounted to the apparatus only when needed, separating the optics from the harmful dusty environment.
2Device complexity
If optics are built into the apparatus chassis, then the structure is integrated, but service and repair require machine downtime and are difficult to achieve on-site
Solution Approach 1:
The optical module is designed with dynamic mounting capabilities, allowing it to be quickly attached and detached from the apparatus chassis. This dynamic interface enables the optical module to be swapped out during routine maintenance without requiring complex disassembly or prolonged machine downtime.
Solution Approach 2:
The optical module is pre-assembled, pre-aligned, and pre-tested in a controlled clean environment before being mounted to the apparatus. This preliminary preparation ensures that when the module is installed, minimal adjustment is needed and the apparatus can return to operation quickly, reducing overall downtime.
3Productivity
If the apparatus operates in a dusty environment with powder, then manufacturing can proceed, but dust infiltrates the machine and causes deterioration in component performance
Solution Approach 1:
The optical module employs a hermetically sealable housing that acts as a protective barrier, preventing dusty ambient air from infiltrating the interior where sensitive optical components are located. This sealing membrane protects the optics while allowing the apparatus to continue operating in dusty manufacturing environments.
Solution Approach 2:
The optical module creates a protected internal environment that isolates sensitive optical components from the harmful dusty external atmosphere. This inert-like protected environment maintains component performance by excluding contaminants while the apparatus operates productively in the dusty manufacturing setting.
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 enables precise control and extended maintenance intervals of the laser beam, improving the accuracy and reliability of the manufacturing process while reducing downtime and maintaining performance in dusty conditions.
Implementation Method 1
containing optical components for focusing and steering the laser beam
Implementation Method 2
containing optical components for focusing and steering the laser beam
Implementation Method 3
The module comprises a sealable housing, for example a hermetically sealable housing containing optical components
Data Source
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AI summary
An additive manufacturing apparatus comprises a processing chamber (100) and an optical module (10). The optical module (10) comprises a housing (20) containing two or more optical trains for delivering laser beams to a planar build surface (130) in the processing chamber (100). Each optical train comprises optical components for focussing and steering the corresponding laser beam.