Serial Fiber Laser Coupling for Dynamic Beam Profile Switching
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Solution Overview
Problem
Current fiber laser technologies require complex configurations and high costs to dynamically adjust beam parameters such as beam diameter and shape for applications like welding, cutting, and additive manufacturing.
Innovation Solution
A simple and cost-effective fiber laser source is achieved by serially coupling two or more fiber lasers, each with distinct optical characteristics, allowing for adjustable beam profiles without compromising beam quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple independent laser sources are coupled into a fiber combiner to achieve adjustable beam profiles, then beam shape control is improved, but device complexity and production cost increase
Solution Approach 1:
The patent combines multiple laser sources (single-mode and multi-mode fibers) into a single hybrid fiber structure, merging their functions while maintaining individual beam characteristics. This integration reduces device complexity compared to using separate fiber combiners while preserving the ability to generate different beam profiles (Gaussian, ring-shaped, flat-top) by controlling the contribution of each fiber type.
Solution Approach 2:
The hybrid fiber structure serves multiple functions simultaneously: it acts as both a single-mode fiber for high-quality Gaussian beams and a multi-mode fiber for ring-shaped and flat-top beams. This multi-functionality eliminates the need for separate dedicated fibers for each beam type, reducing overall system complexity while maintaining adaptability across different beam shape requirements.
2Adaptability or versatility
If multiple independent laser sources are coupled into a fiber combiner to achieve adjustable beam profiles, then beam shape control is improved, but production cost increases
Solution Approach 1:
By merging multiple laser sources into a single hybrid fiber structure, the patent reduces the number of separate components that need to be manufactured and assembled. This consolidation lowers production costs while maintaining the capability to generate various beam profiles through controlled coupling of single-mode and multi-mode fiber outputs.
Solution Approach 2:
The universal hybrid fiber structure can produce multiple beam types (Gaussian, ring-shaped, flat-top) from a single integrated component, eliminating the need for multiple specialized components. This multi-functionality reduces manufacturing complexity and cost while preserving full adaptability for different beam shape requirements.
3Manufacturing precision
If different beam diameters are used for different regions of a part, then manufacturing precision is improved for delicate regions, but productivity decreases due to lower scan speeds
Solution Approach 1:
The patent implements dynamic beam diameter control by enabling real-time switching between different beam profiles (small-diameter Gaussian for high precision, larger ring-shaped or flat-top for faster processing). This dynamic adaptability allows the system to optimize for either precision or speed depending on the specific processing requirements of different regions, resolving the trade-off between manufacturing precision and productivity.
Solution Approach 2:
The system changes beam parameters (diameter, shape, intensity distribution) dynamically based on processing requirements. By adjusting these parameters, the laser can focus to small spots for high-precision work on delicate regions while using larger beam areas for faster processing on less critical regions, thereby maintaining both high precision where needed and high productivity overall.
4Productivity
If multiple laser sources operate in parallel to increase processing speed, then productivity is improved, but device complexity and production cost increase
Solution Approach 1:
The patent merges multiple laser sources into a single hybrid fiber structure that can operate in parallel modes. This integration allows the system to achieve the productivity benefits of multiple sources while reducing the device complexity that would result from using separate parallel laser systems with independent control and delivery mechanisms.
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 configuration enables flexible operation across various regimes, maintaining beam integrity while allowing for adjustments in beam shape, diameter, and power, thereby enhancing the efficiency and versatility of fiber laser applications.
Implementation Method 1
The refractive index profiles of the output beam of the multi-mode fiber laser and the input beam of the single-mode fiber laser are matched so that the single-mode fiber laser guides the beam output by the multi-mode fiber laser
Implementation Method 2
upstream multi-mode fiber laser and a downstream single-mode fiber laser. The refractive index profiles
Data Source
AI summary
A fiber laser source is configured with a plurality of individual fiber lasers which are coupled to one another in series. Each subsequent fiber laser is configured to transmit laser radiation of any of fiber laser or lasers located upstream therefrom. The switching among different operational regimes of the laser source, which includes SM, MM and different MMs and associated therewith beam shape, beam quality and power parameters is provided at high frequency corresponding to on/off switching of each individual fiber laser.