Switchyard Beam Routing for Reusing Rejected Light in 3D Printing
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Solution Overview
Problem
In additive manufacturing, a significant amount of light energy is wasted due to the rejection of unwanted patterns, leading to inefficiencies in power usage and reduced printing rates.
Innovation Solution
A 'switchyard' style optical system that recycles and re-uses rejected light energy by redirecting and re-patterning it, allowing for increased intensity and improved energy efficiency in the additive manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If multiple laser beams are combined and then separated into positive and negative patterned images, then additive manufacturing can be performed, but a significant amount of light energy is wasted due to rejection of unwanted patterns
Solution Approach 1:
The patent recovers rejected light energy by capturing the negative patterned beam that would normally be discarded to a beam dump. This recovered energy is then re-patterened and combined with the positive patterned beam, effectively recovering what would have been wasted energy and converting it into useful printing energy, thereby reducing energy loss and improving productivity
Solution Approach 2:
The patent converts the harmful waste energy (rejected light patterns) into a beneficial resource. By capturing and re-patterening the rejected beams, the system transforms energy that would have been lost into additional useful printing energy, effectively converting a negative aspect into a positive contribution to the manufacturing process
2Loss of energy
If rejected light energy is discarded to a beam dump, then the optical system operates simply, but energy efficiency is reduced and printing rates are limited
Solution Approach 1:
The patent segments the optical system into distinct functional modules: beam combining optics, light valve assemblies for positive and negative patterning, beam routing mirrors, and a beam dump. This segmentation allows the complex energy recovery function to be implemented through coordinated simple components rather than a single complex device, managing system complexity while achieving energy efficiency
Solution Approach 2:
The patent introduces intermediary components (beam routing mirrors and additional light valve assemblies) that mediate between the simple beam dump approach and the desired energy recovery function. These intermediaries enable the complex function of energy recapture and re-patterening without requiring a complete redesign of the entire optical system
3Productivity
If high power laser beams are used to increase printing speed, then productivity improves, but energy waste increases due to pattern rejection
Solution Approach 1:
The patent recovers energy from rejected patterns even when high power laser beams are used. By capturing and re-patterening the rejected beams, the system ensures that the high power input is more fully utilized, reducing the proportion of energy waste while maintaining the high printing speed enabled by high power lasers
Solution Approach 2:
The patent creates a continuous cycle where rejected energy is continuously recaptured, re-patterened, and fed back into the printing process. This continuous recovery and reuse of energy ensures that high power laser beams maintain their productivity benefits while minimizing energy waste through ongoing energy recirculation
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 increases the intensity of the laser beam, enabling faster print rates and higher material conversion rates while maintaining high energy efficiency, allowing for the printing of more complex materials without the need for excessive capital equipment.
Implementation Method 1
A 'switchyard' style optical system that recycles and re-uses rejected light energy by redirecting and re-patterning it
Implementation Method 2
A 'switchyard' style optical system that recycles and re-uses rejected light energy by redirecting and re-patterning it
Implementation Method 3
one patterned beam image used to build parts and the other beam image is discarded into a beam dump. Such patterns can be created by use of a liquid crystal based light valve that allows for the spatial modulation of transmitted or reflected light by rotating the electromagnetic wave polarization state
Data Source
AI summary
A method and an apparatus for additive manufacturing pertaining to high efficiency, energy beam patterning and beam steering to effectively and efficiently utilize the source energy. In one embodiment recycling and reuse of unwanted light includes a source of multiple light patterns produced by one or more light valves, with at least one of the multiple light patterns being formed from rejected patterned light. An image relay is used to direct the multiple light patterns, and a beam routing system receives the multiple light patterns and respectively directs them toward defined areas on a powder bed.