Visible-Laser 3D Printing for Submicron Resolution and Smooth Surfaces
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Solution Overview
Problem
Current 3D printing technologies using infrared lasers face limitations in achieving submicron resolution and high surface smoothness due to slow manufacturing speed and low feature resolution, making them unsuitable for various applications.
Innovation Solution
A system utilizing visible lasers with high power and high brightness, employing stimulated Raman scattering and modular diode laser arrays to produce a small spot size, enabling high-resolution and high-speed 3D printing with improved surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If infrared laser wavelengths are used for 3D printing, then the manufacturing process can be implemented with existing technology, but the resolution is limited and cannot achieve submicron features
Solution Approach 1:
The patent changes the fundamental parameter of laser wavelength from infrared to visible range (400-760 nm). This parameter change enables submicron resolution because visible light has shorter wavelength, allowing the laser spot size to be reduced below 1 micrometer while maintaining high manufacturing speed through direct laser writing
2Manufacturing precision
If infrared lasers are used for layer-by-layer 3D printing, then the process can be simplified, but the surface roughness is high and不适合 for applications requiring smooth surfaces
Solution Approach 1:
The patent changes the laser wavelength parameter to visible range, which enables achieving smooth surfaces with RMS roughness less than 10 nanometers. This is accomplished through direct laser writing that writes complete 3D images in a single pass, eliminating the layer-by-layer deposition process that causes surface roughness, while maintaining high build rates
3Manufacturing precision
If complex optics and beam delivery systems are used to improve resolution, then submicron features can be achieved, but the system complexity increases significantly
Solution Approach 1:
The patent extracts and eliminates the complex layer-by-layer deposition system, scanners, and sophisticated optics. Instead, it uses a simplified direct laser writing approach with a single objective lens to focus the visible laser beam, achieving submicron resolution without complex beam delivery systems by directly writing the 3D image through photopolymerization
Solution Approach 2:
The patent replaces the mechanical layer-by-layer deposition and scanning system with a direct optical writing system. The visible laser directly writes the 3D structure through photopolymerization in a single pass, eliminating the need for mechanical scanners and complex beam delivery systems that would be required with infrared lasers
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 system achieves significantly improved resolution and build rates, allowing for the creation of objects with smooth surfaces and high aspect ratios, overcoming the limitations of infrared laser-based systems.
Implementation Method 1
A method of performing a high power laser operation on a target material to fuse the material together, to cure the materials or to ablate the material, which can be used to form a multilayered 3D object
Implementation Method 2
A method of performing a high power laser operation on a target material to fuse the material together
Implementation Method 3
A method of performing a high power laser operation on a target material to fuse the material together, to cure the materials or to ablate the material
Implementation Method 4
A method of performing a high power laser operation on a target material to fuse the material together, to cure the materials or to ablate the material
Data Source
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AI summary
The Invention relates to a printing system for forming a three-dimensional object. Recognized herein is the need for improved three-dimensional (also "3D" and "3-D" herein) printing systems. In particular, there is the need to address the slow manufacturing speed, low feature resolution and high surface roughness of the part, as may be the case with the use of infrared (IR) lasers to manufacture components on a layer by layer basis. The new printing system comprises a laser light source with an optical fiber (4007) that outputs a coherent beam of visible light with a Rayleigh loss that is less than about 50 db/km; a substrate in optical communication with the laser light source; a scanning module downstream of the laser light source, which is adapted to generate a predetermined scanning motion of said beam with respect to the substrate, which predetermined scanning motion corresponds to a shape of said three-dimensional object; and a computer control system operatively coupled to the laser light source and the scanning module, which is programmed to control the scanning motion and to modulate a power of the laser light source, to form the object from the substrate.