Switchyard Beam Routing for Reusing Rejected Patterned Light
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Solution Overview
Problem
Existing systems for redirecting laser beams in additive manufacturing face inefficiencies due to the rejection of unwanted light patterns, leading to energy loss and reduced throughput.
Innovation Solution
A 'switchyard' optical system that recycles and re-uses rejected light energy by redirecting it through a series of switch points, allowing for its reuse in the additive manufacturing process, either in a homogenized form or as patterned light to maintain high power efficiency and throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If multiple laser beams are combined and split into patterned images using a light valve, then additive manufacturing capability is achieved, but rejected light patterns are discarded causing energy loss
Solution Approach 1:
The patent recovers rejected light patterns by redirecting them through a beam enclosure system with turning mirrors instead of discarding them in a beam dump. The rejected light is routed to alternative destinations where it can be reused or effectively utilized, thereby reducing energy loss while maintaining the necessary beam splitting and patterning functionality.
Solution Approach 2:
The beam enclosure system serves multiple functions: it redirects the primary laser beams to the target chamber, routes rejected light patterns to alternative destinations, and provides a flexible framework for future expansion. The turning mirrors and beam routing infrastructure can accommodate additional beams or alternative light paths without requiring complete system redesign.
2Productivity
If rejected light is discarded to a beam dump, then beam routing is simplified, but system intensity and printing rates are reduced
Solution Approach 1:
Instead of permanently discarding rejected light in a beam dump, the system recovers it by implementing a beam enclosure with turning mirrors that redirect the rejected patterns to alternative destinations. This recovery mechanism increases the effective system intensity by utilizing light that would otherwise be wasted, thereby improving printing rates and productivity.
Solution Approach 2:
The beam enclosure system enables continuous utilization of light energy by redirecting rejected patterns into useful pathways rather than allowing them to terminate in a beam dump. This continuous action maximizes the productive use of laser energy throughout the additive manufacturing process.
3Loss of energy
If a beam enclosure with turning mirrors is used to redirect beams, then energy efficiency is improved, but system complexity increases
Solution Approach 1:
The beam enclosure system with turning mirrors is designed to perform multiple functions simultaneously: redirecting primary laser beams to the target chamber, routing rejected light patterns to alternative destinations, and providing a scalable framework for future system expansion. This multi-functionality justifies the increased complexity by delivering multiple benefits from a single integrated infrastructure.
Solution Approach 2:
The turning mirrors act as intermediaries that facilitate the redirection of both primary and rejected light beams. These intermediary elements enable efficient energy routing by mediating between the light valve, the target chamber, and alternative destinations for rejected patterns, thereby reducing overall energy loss in the system.
4Use of energy by stationary object
If rejected light patterns are reused, then energy costs are reduced, but beam routing complexity increases
Solution Approach 1:
The system recovers rejected light patterns by implementing a beam enclosure with turning mirrors that redirect these patterns to alternative destinations where they can be reused. This recovery process reduces the energy costs of the additive manufacturing system by utilizing light that would otherwise be discarded, while the modular beam routing design manages the associated complexity.
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 increases system intensity, reduces energy costs, and enhances printing rates by effectively re-distributing light power, enabling higher intensity and faster print times.
Implementation Method 1
A beam enclosure redirects multiple incoming laser beams to a top and bottom of a target chamber. After laser beams travel through the laser bays, they enter a system of beam enclosures with turning mirrors that redirect the beam to the upper and lower hemispheres of the target chamber.
Implementation Method 2
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.
Implementation Method 3
one type of diode laser additive manufacturing involve combining multiple beams into a single beam
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.