Switchyard Beam Routing for Recycled Light in Powder Bed 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
The implementation of 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
1Illumination intensity
If a liquid crystal based light valve is used to create patterned beams, then spatial modulation of light is achieved, but a significant amount of light energy is wasted due to rejection of unwanted patterns
Solution Approach 1:
The patent implements a switchyard optical system that captures and redirects the rejected light energy from the light valve instead of discarding it to a beam dump. The system uses multiple mirrors and beam combining optics to recover the unwanted light patterns and redirect them to additional build platforms, thereby recovering energy that would otherwise be lost.
Solution Approach 2:
The patent introduces a switchyard optical system as an intermediary between the light valve and the build platforms. This intermediary system includes mirrors, beam combining optics, and routing mechanisms that enable the redistribution of light energy, including the previously rejected patterns, to multiple destinations where they can be productively used.
2Productivity
If multiple beams are combined into a single beam and then separated into patterned images, then additive manufacturing capability is achieved, but energy efficiency is reduced due to beam rejection
Solution Approach 1:
The patent creates a multi-functional optical system where a single light source serves multiple build platforms simultaneously. The switchyard system distributes light energy to multiple destinations, allowing the same light source to perform additive manufacturing on several platforms at once, thereby improving overall system productivity and energy utilization efficiency.
Solution Approach 2:
The patent combines multiple beam paths and uses beam combining optics to merge light energy from a single source into multiple patterned beams that can be distributed to different build platforms. This merging approach allows efficient utilization of the light source while maintaining the capability to create multiple patterned images simultaneously.
3Reliability
If rejected light energy is discarded to a beam dump, then unwanted patterns are removed, but energy costs increase and print rates decrease
Solution Approach 1:
The patent converts the harmful effect of rejected light energy (which would otherwise be wasted heat in a beam dump) into a beneficial resource by redirecting it to additional build platforms. The previously unwanted light patterns become useful for manufacturing additional parts, transforming energy waste into productive output and improving material conversion rates.
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 approach enhances the intensity of the light used for printing, reduces energy costs, and enables faster print rates and higher material conversion rates by effectively re-distributing the recycled light, thereby improving the overall efficiency of the additive manufacturing process.
Implementation Method 1
A switchyard style optical system includes a first set of mirrors arranged to receive a first patterned light beam and arrange the first patterned light beam in a first desired configuration. A second set of mirrors is arranged to receive a second patterned light beam and arrange the second patterned light beam in a second desired configuration.
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.
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.