Split Laser Beam Energy Control for Faster Additive Manufacturing
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Solution Overview
Problem
Existing laser additive manufacturing methods suffer from slow scanning speeds and low manufacturing efficiency due to the point-to-point processing of a single laser beam and restrictions on object size caused by the intersection angle of the laser beam with the platform.
Innovation Solution
A laser energy managing device comprising a laser beam splitting device, micro-bending device, and controller that splits and micro-bends laser beams to distribute energy evenly across multiple transmission channels, allowing for real-time control of energy output and increased manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single laser beam is used for point-to-point processing, then the manufacturing precision can be maintained, but the scanning speed and productivity are reduced
Solution Approach 1:
The patent applies segmentation by dividing a single laser beam into multiple split beams using optical beam splitters. This allows simultaneous processing of multiple points on the material surface, transforming sequential point-to-point processing into parallel multi-point processing, thereby significantly increasing scanning speed and productivity while maintaining processing precision through independent control of each beam
2Adaptability or versatility
If the laser beam intersection angle with the platform is reduced, then the manufacturing adaptability increases, but the energy density of the projected spot decreases
Solution Approach 1:
The patent resolves this contradiction by transitioning from single-beam processing to multi-beam parallel processing. By distributing multiple beams across different spatial positions and angles, the system can process larger areas and more complex geometries (improving adaptability) while each individual beam maintains its high energy density through focused delivery, achieving both goals simultaneously
3Productivity
If multiple laser beams are used for parallel processing, then the productivity increases, but the device complexity increases
Solution Approach 1:
The patent applies universality by using a single laser generator that produces one laser beam, which is then optically split into multiple beams. This multi-functional approach allows one laser source to perform multiple processing tasks simultaneously, increasing productivity while avoiding the complexity of multiple independent laser generators. The optical splitting system provides a unified control architecture for all beams
4Productivity
If the laser beam is split into multiple channels, then the manufacturing efficiency improves, but the energy distribution control becomes more difficult
Solution Approach 1:
The patent implements feedback control mechanisms for each split beam channel, allowing real-time monitoring and adjustment of energy distribution. This enables precise control of laser energy across multiple beams, ensuring optimal energy delivery to different processing zones while maintaining the productivity benefits of parallel processing
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 enhances manufacturing efficiency by enabling faster scanning and larger object production capabilities through precise control of laser energy distribution, allowing for simultaneous processing of material areas with multiple controllable laser beams.
Implementation Method 1
The micro-bending device is configured to micro-bend the split transmission channels to attenuate corresponding split laser beams transmitted thereby
Data Source
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AI summary
A laser energy managing device comprises: a laser beam splitting device, at least one micro-bending device, and a controller. The laser beam splitting device is configured to split an input laser beam from a laser generator into a plurality of split laser beams, and comprises a plurality of split transmission channels configured to transmit the plurality of split laser beams respectively. The at least one micro-bending device is configured to micro-bend the split transmission channels to attenuate corresponding split laser beams transmitted thereby and thus obtain a plurality of output laser beams. The controller is configured to control a micro-bending degree of each split transmission channel.