VCSEL Array for Parallel Powder Bed Fusion Melting
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Solution Overview
Problem
Current additive manufacturing systems using single scanning mirrors are limited by slow build speeds due to serial layer scanning, and alternative methods with masks are inefficient in terms of laser power usage, leading to prolonged processing times, especially in complex geometries like airfoil fabrication.
Innovation Solution
The integration of a vertical-cavity surface-emitting laser (VCSEL) array in powder bed fusion systems allows for simultaneous full-pattern creation by using an array of VCSELs on silicon chips with modulated power and precise control over each laser spot, enabling faster and more efficient melting of powder layers with reduced laser power requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single scanning mirror is used to direct a high power laser beam serially along the outline of each layer, then manufacturing precision can be maintained, but build speed becomes very slow requiring days of processing time
Solution Approach 1:
The patent divides the single laser beam into multiple independent laser beams arranged in an array. Each VCSEL element in the array can independently scan and melt powder in parallel, transforming a serial process into a parallel process while maintaining the precision of individual beam control.
Solution Approach 2:
The patent transitions from a single-dimensional scanning approach to a two-dimensional array of laser beams. The VCSEL array allows simultaneous scanning across multiple locations in the X-Y plane, adding a spatial dimension to the melting process and dramatically increasing build speed.
2Productivity
If a mask is used to select a small area of a wide beam to the powder at one time, then full section building at a time is enabled, but laser power efficiency becomes very poor requiring dumping of most laser power
Solution Approach 1:
Instead of using a mask to block most of the laser power, the patent segments the laser source into an array of VCSELs, each emitting a focused beam only where needed. This eliminates the waste of generating and then blocking laser power, directing energy precisely to the melt zones.
Solution Approach 2:
The patent applies laser energy locally and selectively at each VCSEL position rather than using a wide beam with a mask. Each VCSEL element delivers concentrated power only to its specific target area, optimizing laser power efficiency while enabling full section building.
3Reliability
If a single high power laser beam is used to scan each layer, then melting of powder can be achieved, but the process requires many thousands of layers to be built sequentially taking days to complete
Solution Approach 1:
The patent segments the single laser beam into multiple VCSEL beams that operate in parallel. While each individual beam maintains the melting capability of the original single beam, the parallel operation of dozens of beams simultaneously processes multiple layers or regions, reducing total processing time from days to hours.
Solution Approach 2:
The VCSEL array enables continuous parallel melting action across multiple locations simultaneously. Instead of sequentially completing one layer before moving to the next, the system performs useful melting action continuously across the entire build area, eliminating idle time between operations.
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 significantly reduces build time, enhances precision, and improves efficiency by allowing parallel operations, achieving comparable melting results with lower laser power and shorter processing times compared to traditional systems, while also reducing maintenance and production costs.
Implementation Method 1
an array of vertical-cavity surface-emitting lasers (VCSEL) in powder bed fusion additive manufacturing (PBFAM) systems and processes to allow for the creation of full patterns simultaneously
Implementation Method 2
selectively fusing the powder within a layer using a high-power laser
Data Source
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AI summary
A method of forming a build in a powder bed includes emitting a plurality of laser beams from selected vertical -cavity surface emitting lasers (VCSELs) of at least one VCSEL array onto the powder bed, the selected VCSELs of the at least one VCSEL array corresponding to a pattern of a layer of the build; and simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build.