Solid-State Patterned Light Routing for Additive Manufacturing Throughput
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Solution Overview
Problem
Laser-based additive manufacturing systems face high costs and inefficiencies due to the use of optomechanical systems for light routing, which are prone to misalignment and waste energy by discarding unused light patterns.
Innovation Solution
An optical system that recycles and re-uses rejected light energy through a solid-state routing subsystem, utilizing beam shaping optics, energy patterning units, and image relays to redirect and reuse unwanted light patterns, increasing system efficiency and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optomechanical systems are used for light routing, then light can be directed to the powder bed, but the system becomes costly and difficult to control due to calibration requirements and susceptibility to damage or misalignment
Solution Approach 1:
The patent replaces optomechanical light routing systems with a digital light processing system that uses a digital micromirror device (DMD) and solid-state components. The DMD electronically directs light patterns without moving mechanical parts, eliminating calibration requirements and susceptibility to vibration-induced misalignment while maintaining reliable light delivery to the powder bed
2Loss of energy
If light is patterned by masks or optical light valves, then spatial modulation of light is achieved, but energy efficiency decreases because unused light is discarded
Solution Approach 1:
The patent recovers and recycles the negative image light that would otherwise be discarded. The DMD directs both the positive image light (used for building parts) and the negative image light (previously wasted) onto the powder bed, enabling simultaneous processing of multiple areas and improving overall energy utilization efficiency
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 energy enhances system throughput and intensity, allowing for higher printing rates and reduced energy consumption, while eliminating the need for costly and fragile optomechanical systems.
Implementation Method 1
a liquid crystal based light valve that allows for the spatial modulation of transmitted or reflected light by rotating the electromagnetic wave polarization state
Implementation Method 2
An optical system that recycles and re-uses rejected light energy through a solid-state routing subsystem, utilizing beam shaping optics, energy patterning units, and image relays to redirect and reuse unwanted light patterns
Data Source
AI summary
A solid state beam routing apparatus includes a controller and a spatial angular light valve arranged to direct a two-dimensional patterned light beam through a predetermined angle in response to an applied voltage. A bed is arranged to receive the two-dimensional patterned light beam as a succession of tiles. In some embodiments, one or more solid state galvo mechanisms are used to direct the two-dimensional patterned light beams formed by the light valve to the multiple powder bed chambers.