Variable Beam Characteristics Fiber for Additive Manufacturing
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Solution Overview
Problem
Current fiber-coupled laser systems require complex and costly mechanisms to adjust beam characteristics, often relying on free-space optics that increase cost, complexity, and reduce reliability, failing to provide optimal performance for various materials processing tasks.
Innovation Solution
The development of a method and apparatus that adjusts optical beam characteristics within a fiber laser system by perturbing the fiber's refractive index profile and confinement regions, allowing for variable beam characteristics without the need for free-space optics, using techniques such as bending, acousto-optic excitation, or thermal perturbation to modify beam parameters like spot size, divergence, and wavelength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If free-space optics or complex mechanisms are used to adjust beam characteristics, then beam parameter adjustability is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent replaces mechanical free-space optics systems with an all-fiber solution that uses fiber bending and refractive index profile modifications to adjust beam characteristics. This substitution eliminates complex mechanical components while achieving the same beam parameter adjustment functionality through optical field control within the fiber medium.
Solution Approach 2:
The patent combines multiple functions (beam delivery, beam parameter adjustment, and beam shaping) into a single integrated fiber optic system. By merging these previously separate functions into one fiber-based platform, the system reduces overall complexity while maintaining full adjustability of beam characteristics.
2Adaptability or versatility
If free-space optics are used to vary beam characteristics, then beam parameter flexibility is improved, but reliability deteriorates due to additional components
Solution Approach 1:
The patent replaces unreliable mechanical free-space optics components with a robust all-fiber system that has no moving parts. This substitution significantly improves reliability by eliminating mechanical failure points while preserving full beam parameter flexibility through fiber-based optical control.
3Adaptability or versatility
If zoom lenses or motorized lenses are used to adjust spot size, then beam characteristic variability is improved, but cost increases significantly
Solution Approach 1:
The patent replaces expensive motorized zoom lenses with a cost-effective fiber-based solution that uses refractive index profile control and fiber bending to achieve spot size variability. This substitution dramatically reduces system cost while maintaining the ability to vary beam characteristics.
Solution Approach 2:
The patent changes the refractive index profile parameters of the fiber to control beam characteristics. By modifying optical parameters rather than using mechanical lens systems, the solution achieves spot size variability at a fraction of the cost of traditional approaches.
4Adaptability or versatility
If multiple optical components are added to achieve variable beam characteristics, then beam parameter adjustability is improved, but optical loss increases
Solution Approach 1:
The patent merges beam delivery and beam parameter adjustment into a single fiber optic pathway, eliminating the need for multiple separate optical components. This integration maintains optical efficiency by keeping the beam confined within the fiber medium throughout the adjustment process, minimizing transmission losses.
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
Enables flexible and efficient adjustment of beam characteristics within fiber lasers, reducing costs and complexity while maintaining performance, allowing for optimized processing of different materials without the need for additional optical components.
Implementation Method 1
perturbing an optical beam propagating within a first length of fiber to adjust one or more beam characteristics of the optical beam
Implementation Method 2
perturbing the fiber's refractive index profile and confinement regions, allowing for variable beam characteristics without the need for free-space optics, using techniques such as bending, acousto-optic excitation, or thermal perturbation
Implementation Method 3
perturbing the fiber's refractive index profile and confinement regions, allowing for variable beam characteristics without the need for free-space optics, using techniques such as bending, acousto-optic excitation, or thermal perturbation
Data Source
AI summary
Additive manufacturing systems and methods for fabricating an article are provided. The additive manufacturing system may include a substrate and a layering device configured to fabricate a first layer of the article on the substrate. The layering device may include an optical beam source configured to generate an optical beam and a variable beam characteristics (VBC) fiber operably coupled with the optical beam source and configured to modify one or more beam characteristics, such as a wavelength, of the optical beam.