Split Flat-Field Optics for Consistent 3D Printing Focus
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Solution Overview
Problem
Three-dimensional printing systems face challenges in maintaining consistent focus and power distribution of a radiation beam over the build plane, leading to inconsistent results due to variations in spot shape and material properties.
Innovation Solution
A three-dimensional printing system incorporating a motorized build platform, a material coating module, and a beam generation module with a flat field focusing system, which includes an input and output component to reduce optical artifacts like spherical aberration and coma, ensuring a consistent laser spot size across the build plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fully integrated flat field correcting system is used to reduce optical artifacts, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The flat field correcting system is divided into separate input and output components rather than using a single integrated system. This segmentation allows each component to be optimized independently and reduces the overall complexity while maintaining focus consistency across the build plane.
Solution Approach 2:
The patent applies different optical corrections at different locations in the beam path by using separate input and output flat field components. This allows localized optimization of focus quality at specific points in the scanning path without requiring a completely complex integrated system.
2Manufacturing precision
If the size of an undivided flat field correcting system is increased to reduce optical artifacts, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
By segmenting the flat field correcting system into separate input and output components, the patent achieves spot size consistency without requiring a single large, expensive integrated system. Each component can be manufactured independently at smaller scale, reducing overall cost.
Solution Approach 2:
The patent applies flat field correction at two separate points (input and output) rather than using a single excessive correction system. This partial application of correction at multiple stages achieves the desired spot size consistency more cost-effectively than a single large correction system.
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 system achieves more dimensionally accurate 3D articles by maintaining consistent laser focus and power distribution, reducing errors at a lower cost compared to scaling up a fully integrated flat field correcting system.
Implementation Method 1
a laser beam-induced solidification or fusion of layers of material
Implementation Method 2
the laser beam should have a consistent focus over the area which is otherwise referred to as a build plane
Implementation Method 3
The flat field focusing system is configured to focus the laser beam across the build plane and includes an input component and an output component
Implementation Method 4
The flat field focusing system of the present disclosure reduces various optical artifacts including spherical aberration, coma, astigmatism, and focal plane curvature errors over the build plane
Data Source
AI summary
A three-dimensional printing system includes a motorized build platform, a material coating module, and a beam generation module. The beam generation module includes a laser beam formation unit, a scan module, and flat field focusing system. The laser beam formation unit includes a laser configured to output a laser beam. The scan module is configured to receive the laser beam and to scan the laser beam over a build plane that is above the motorized build platform. The flat field focusing system is configured to focus the laser beam across the laser beam and includes an input component and an output component. The input component is configured to receive the laser beam from the beam formation unit and to pass the laser beam to the scan module. The output component is configured to receive the laser beam from the scan module and pass the laser beam to the build plane.