CN117884656A - A face region print system for laser material increase makes - Google Patents
A face region print system for laser material increase makes Download PDFInfo
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- CN117884656A CN117884656A CN202410022105.0A CN202410022105A CN117884656A CN 117884656 A CN117884656 A CN 117884656A CN 202410022105 A CN202410022105 A CN 202410022105A CN 117884656 A CN117884656 A CN 117884656A
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- 239000000463 material Substances 0.000 title claims abstract description 20
- 238000007639 printing Methods 0.000 claims abstract description 30
- 238000004519 manufacturing process Methods 0.000 claims abstract description 25
- 230000003287 optical effect Effects 0.000 claims abstract description 25
- 239000000654 additive Substances 0.000 claims abstract description 22
- 230000000996 additive effect Effects 0.000 claims abstract description 22
- 238000007493 shaping process Methods 0.000 claims abstract description 11
- 230000005540 biological transmission Effects 0.000 claims abstract description 4
- 230000010287 polarization Effects 0.000 claims description 30
- 239000011159 matrix material Substances 0.000 claims description 9
- 238000012544 monitoring process Methods 0.000 claims description 3
- 238000003854 Surface Print Methods 0.000 claims 3
- 230000004927 fusion Effects 0.000 abstract description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 11
- 229910052802 copper Inorganic materials 0.000 description 11
- 239000010949 copper Substances 0.000 description 11
- 238000010521 absorption reaction Methods 0.000 description 6
- 238000010146 3D printing Methods 0.000 description 5
- 230000008901 benefit Effects 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 3
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 3
- 229910052737 gold Inorganic materials 0.000 description 3
- 239000010931 gold Substances 0.000 description 3
- 230000033001 locomotion Effects 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- 238000010276 construction Methods 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 238000000059 patterning Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000002310 reflectometry Methods 0.000 description 2
- 239000004988 Nematic liquid crystal Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 230000008094 contradictory effect Effects 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000007499 fusion processing Methods 0.000 description 1
- 239000004973 liquid crystal related substance Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000013307 optical fiber Substances 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
Classifications
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
The invention provides a face area printing system for laser additive manufacturing, comprising: the green laser emits laser beams, the laser beam transmission direction is changed through a reflecting mirror, the laser beams are shaped into square light spots through a beam shaping module, the square light spots are uniformly processed through a light homogenizing sheet, the uniformly processed laser beams enter a phase modulation module to be subjected to phase modulation, the laser beams after phase modulation and the light beams emitted by pattern indication light are jointly transmitted to an optical addressable light valve through a first spectroscope, the optical addressable light valve carries out patterned deflection modulation on mixed laser beams, S polarized light beams in the modulated laser beams are reflected to a beam collector through a polarized beam splitter, P polarized light beams in the laser beams are transmitted to a second spectroscope through the polarized beam splitter, and the light beam deflection enters a working face through a scanning system to carry out laser material increasing processing. The invention can realize the fusion forming of a region by one pulse, and improves the processing efficiency on the basis of not increasing the laser quantity.
Description
Technical Field
The invention relates to the technical field of 3D printing, in particular to a surface area printing system for laser additive manufacturing.
Background
Most of the current laser additive manufacturing equipment is based on a laser selective melting forming process, and the forming from point to line, line to surface and surface to body is realized through powder layer-by-layer melting and superposition, so that the forming efficiency and the forming size are greatly limited. In order to effectively improve the forming efficiency and size of the equipment, the suppliers adopt a mode of increasing the number of lasers. However, on one hand, the increase of the number of the laser means the increase of the number of the splicing areas, and the splicing quality is related to a plurality of factors such as temperature drift, mechanical structure stability and the like of the vibrating mirror working for a long time, and the more the splicing areas are, the greater the difficulty of guaranteeing the splicing quality is, and the higher the risk of quality problems of products is. On the other hand, introducing multiple lasers not only increases the equipment cost, but also increases the number of vibrating mirrors along with the increase of the number of lasers, accurate calibration and special thermal management are needed for accurate printing, the complexity of the system is greatly increased, and the practical production and application are not facilitated. In addition, the high heat conductivity of the high-reflection materials such as copper and the limitation of the characteristics such as high reflection of laser, and the like make the forming process control of the additive manufacturing technology of the high-reflection material powder difficult, the forming difficulty is high, and the research and application of the 3D printing copper are behind some other common metal materials. Copper is a typical structural and functional integrated material, has wide additive manufacturing requirements, and is a research hotspot in the 3D printing industry. While densification of the shaped article can currently be achieved by increasing the laser power and optimizing the shaping process, the laser light reflected back into the optical system can damage the optical coating, further damaging the laser. Thus relying solely on improving the beam quality of the laser and increasing the laser power is not an effective viable solution.
Disclosure of Invention
The technical problems to be solved by the invention are as follows: a face area printing system for laser additive manufacturing is provided to improve processing efficiency.
In order to solve the technical problems, the invention adopts the following technical scheme: the surface area printing system for laser additive manufacturing comprises a green laser and a laser working module, wherein the laser working module comprises a reflecting mirror, a beam shaping module, a light homogenizing sheet, a phase modulation module, pattern indicating light, a first spectroscope, an optically addressable light valve, a polarizing beam splitter, a second spectroscope and a scanning system;
The green laser emits laser beams, the laser beam transmission direction is changed through a reflecting mirror, the laser beams are shaped into square light spots through a beam shaping module, the square light spots are uniformly processed through a light homogenizing sheet, the uniformly processed laser beams enter a phase modulation module to be subjected to phase modulation, the laser beams after phase modulation and the light beams emitted by pattern indication light are transmitted to an optical addressable light valve through a first spectroscope together, the optical addressable light valve carries out patterned deflection modulation on mixed laser beams, S polarized light beams in the modulated laser beams are reflected to a beam collector through a polarization beam splitter, P polarized light beams in the laser beams are transmitted to a second spectroscope through the polarization beam splitter, and the light beam deflection enters a working face through a scanning system to carry out laser material increase processing.
Further, the beam shaping module comprises a vertically arranged cylindrical lens and a horizontally arranged cylindrical lens, and the laser beam passes through the vertically arranged cylindrical lens and then passes through the horizontally arranged cylindrical lens.
Further, the phase modulation module comprises a first wave plate, a polarizer, an SLM and a second wave plate; the first wave plate and the polarizer modulate the laser beam, then the SLM is utilized to modulate the Gaussian beam into a Bessel beam, and the Bessel beam enters the second wave plate for phase compensation.
Further, if the polarization state of the initial laser beam of the green laser is horizontal polarization, a modulation formula adopted by the phase modulation module is:
S out1 represents the Stokes vector of the emergent light beam after passing through the first wave plate, M p1 represents the Mueller matrix of the first wave plate, S in represents the Stokes vector of the polarization state of the light beam, and the output of the laser is circularly polarized light after the horizontal polarized light is outputted by the laser and modulated by the first wave plate according to the formula (1);
S out2 represents the Stokes vector of the outgoing beam after passing through the polarizer, M q represents the Mueller matrix of the polarizer, and the circularly polarized light obtained by the formula (2) is output as extraordinary light after being modulated by the polarizer.
Further, the phase modulation module comprises a polarizer, an SLM and a second wave plate; the polarizer modulates the laser beam, then the SLM modulates the Gaussian beam into a Bessel beam, and the Bessel beam enters the second wave plate for phase compensation.
Further, if the polarization state of the initial laser beam of the green laser is circularly polarized, the modulation formula adopted by the phase modulation module is as follows:
s out3 represents the Stokes vector of the emergent light beam after passing through the second wave plate, M p2 represents the Mueller matrix of the second wave plate, S out2 represents the Stokes vector of the emergent light beam after passing through the polarizer, and the extraordinary light is obtained by the formula (3) and is output as horizontally polarized light after being modulated by the second wave plate.
Further, the pattern indicates that the light beam emitted by the light is 450nm.
Further, the area printing system for laser additive manufacturing further comprises an attenuation sheet, an optical filter and a detector; and part of light reflected by the working surface is transmitted into the attenuation sheet and the optical filter through the second beam splitter and then received by the detector.
Further, the detector is a PD or CCD for power and image monitoring of the print processing surface.
The invention has the beneficial effects that: the surface area printing system adopting the structure can realize the fusion forming of a region by one pulse, improves the processing efficiency on the basis of not increasing the laser quantity, has higher laser absorption efficiency to high-reflection materials by adopting a green laser, can improve the material forming efficiency and the processing quality, can effectively reduce the power requirement to the laser, and also greatly reduces the damage threshold requirement to optical elements in the system due to the low reflectivity of the laser.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions of the prior art, the drawings which are used in the description of the embodiments or the prior art will be briefly described, it being obvious that the drawings in the description below are only some embodiments of the invention, and that other drawings can be obtained from the mechanisms shown in these drawings without the need for inventive labour for a person skilled in the art.
Fig. 1 is a schematic diagram of a surface area printing system for laser additive manufacturing according to an embodiment of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are only some, but not all embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It should be noted that the description of "first," "second," etc. in this disclosure is for descriptive purposes only and is not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include at least one such feature. In addition, the technical solutions of the embodiments may be combined with each other, but it is necessary to base that the technical solutions can be realized by those skilled in the art, and when the technical solutions are contradictory or cannot be realized, the combination of the technical solutions should be considered to be absent and not within the scope of protection claimed in the present invention.
As shown in fig. 1, an embodiment of the present invention is: a surface area printing system for laser additive manufacturing comprises a green laser and a laser working module, wherein the laser working module comprises a reflecting mirror, a beam shaping module, a light homogenizing sheet, a phase modulation module, pattern indicating light, a first spectroscope, an Optically Addressable Light Valve (OALV), a Polarizing Beam Splitter (PBS), a second spectroscope and a scanning system;
The green laser emits laser beams, the laser beam transmission direction is changed through a reflecting mirror, the laser beams are shaped into square light spots through a beam shaping module, the square light spots are uniformly processed through a light homogenizing sheet, the uniformly processed laser beams enter a phase modulation module to be subjected to phase modulation, the laser beams after phase modulation and the light beams emitted by pattern indication light are transmitted to an Optical Addressable Light Valve (OALV) through a first spectroscope together, the Optical Addressable Light Valve (OALV) carries out patterned deflection modulation on mixed laser beams, S polarized light beams in the modulated laser beams are reflected into a beam collector through a Polarization Beam Splitter (PBS), P polarized light beams in the laser beams are transmitted to a second spectroscope through the Polarization Beam Splitter (PBS), and the light beam deflection enters a working face through a scanning system to carry out laser material increasing processing.
In this scheme, adopt the regional printing system of face of this structure for the formation of melting of a slice region can be realized to a pulse, improves machining efficiency on the basis that does not increase laser quantity, and green laser is higher to the laser absorption efficiency of high-reflection materials such as copper, gold, not only can promote material forming efficiency and processingquality, can also effectively reduce the power requirement to the laser, also reduces the damage threshold requirement of optical element in the system by a wide margin to the low reflectivity of laser simultaneously, more does benefit to industrial realization.
The beam shaping module comprises a vertically arranged cylindrical lens and a transversely arranged cylindrical lens, and the laser beam passes through the vertically arranged cylindrical lens and then passes through the transversely arranged cylindrical lens.
The surface area printing system for laser additive manufacturing further comprises an attenuation sheet, an optical filter and a detector; and part of light reflected by the working surface is transmitted into the attenuation sheet and the optical filter through the second beam splitter and then received by the detector.
The detector is PD or CCD, which is used to monitor the power and image of the printing surface. Therefore, the real-time adjustment of the incident laser parameters is realized, and the better workpiece forming quality is obtained. And the scanning system is used for adjusting and realizing the light beam scanning within a certain range, the movement of a working surface is not required, and the processing precision is improved.
Wherein the pattern indicates that the light beam emitted by the light is 450nm.
In a specific embodiment, the phase modulation module comprises a first wave plate, a polarizer, an SLM and a second wave plate; the first wave plate and the polarizer modulate the laser beam, then the SLM is utilized to modulate the Gaussian beam into a Bessel beam, and the Bessel beam enters the second wave plate for phase compensation.
Wherein, the initial laser beam polarization state of the green laser is horizontal polarization, and the modulation formula adopted by the phase modulation module is:
S out1 represents the Stokes vector of the emergent light beam after passing through the first wave plate, M p1 represents the Mueller matrix of the first wave plate, S in represents the Stokes vector of the polarization state of the light beam, and the output of the laser is circularly polarized light after the horizontal polarized light is outputted by the laser and modulated by the first wave plate according to the formula (1);
s out2 represents the Stokes vector of the outgoing beam after passing through the polarizer, M q represents the Mueller matrix of the polarizer, and the circularly polarized light obtained by the formula (2) is output as extraordinary light after being modulated by the polarizer. The extraordinary beam is modulated with an SLM to obtain a bessel beam.
Gaussian beams in an optical path system are modulated into Bessel beams by using an SLM, so that the energy of the center of a light spot is dispersed to the periphery, and the propagation loss of the optical path and the thermal gradient of a printing surface can be effectively reduced by designing the profile distribution of the light spot, so that a forming part with a more compact and firm structure is obtained. And the SLM has programmable characteristics, can realize dynamic control of light beams, and can generate any light field according to different modulation requirements. However, the SLM does not act on the ordinary component of the laser beam, but acts only on the extraordinary component, so that the polarization state of the beam needs to be modulated by the first wave plate and the polarizer in the phase modulation module.
In a specific embodiment, the phase modulation module comprises a polarizer, an SLM and a second wave plate; the polarizer modulates the laser beam, then the SLM modulates the Gaussian beam into a Bessel beam, and the Bessel beam enters the second wave plate for phase compensation.
Wherein, the initial laser beam polarization state of the green laser is circular polarization, and the modulation formula adopted by the phase modulation module is:
s out3 represents the Stokes vector of the emergent light beam after passing through the second wave plate, M p2 represents the Mueller matrix of the second wave plate, S out2 represents the Stokes vector of the emergent light beam after passing through the polarizer, and the extraordinary light is obtained by the formula (3) and is output as horizontally polarized light after being modulated by the second wave plate.
If the initial beam polarization state of the laser is circular polarization, the first wave plate in the phase modulation module can be removed, and the laser beam is modulated only by using the polarizer, specifically as shown in the formula (2).
An Optically Addressable Light Valve (OALV) is composed of nematic liquid crystal sandwiched between a photoconductor and a transparent conductor for switching polarization selection, a patterned beam of light emitted by patterned indication light enters a photoconductive layer of the Optically Addressable Light Valve (OALV), the liquid crystal is aligned with an applied field, the region coincident with the pattern is not rotated in polarization, and a horizontal polarization state is maintained; the region not overlapping the pattern rotates the polarization, modulating the polarization state to a vertical output.
The laser beam with the pattern after the patterning modulation of the Optically Addressable Light Valve (OALV) enters a scanning system, firstly, the incident patterned laser beam is reflected in the X-Y direction, and the movement of the lens is realized through the rotation of a motor, so that a set scanning motion track is formed. And secondly, modulating the patterned laser into the size of the target surface area through a focusing mirror in a scanning system to obtain larger laser energy density, and then entering a working surface to melt and shape the material surface area.
Compared with the traditional laser point-by-point printing mode, the surface area printing technology adopted by the technical scheme changes the polarization state of laser light by patterning, and melts one patterned area at a time, namely one pulse to realize the forming of one area, the construction speed is improved by thousands of times, and the processing efficiency and the production cost of the metal 3D printing equipment are improved by orders of magnitude. For the laser, the laser selective area molten metal 3D printing equipment on the market at present basically adopts an optical fiber laser, uses infrared laser as a beam source, has the advantages of less energy absorption and difficult forming for high-reflection materials such as copper, gold and the like, and has the advantages of high absorption efficiency, less printing splashing and the like when the laser absorption rate of copper to the laser with the wavelength of 515nm is higher than 60%, so that the laser wavelength is reduced, and the increase of the laser absorption rate of copper to the laser is the key for realizing the additive manufacturing of the high-reflection materials such as copper and the like.
Compared with the prior art, the embodiment has the following advantages:
1) Because the absorptivity of copper to infrared wavelength is less than 5%, the efficiency of processing high-reflection materials such as copper, gold and the like by using infrared light is extremely low, 95% of laser light can be reflected by the materials, meanwhile, the optical elements in an optical path and the laser can be damaged, the absorptivity of copper to green light wavelength is more than 60%, the infrared laser in the existing equipment is replaced by the green light laser, the requirement on the output power of the laser can be reduced to a great extent, the requirement on the damage threshold value of the optical elements in a system can be reduced, and the method is easier to apply and realize industrially.
2) The area printing technology enables one pulse to realize the fusion forming of a sheet area, and the Optical Addressable Light Valve (OALV) is utilized to carry out patterned polarization modulation on a laser beam, wherein the pattern indication light can realize the control of laser point power and exposure time through the gray adjustment of each pixel, so that the area printing can better control the fusion process, and further realize high-resolution printing, manufacturing gradient materials, carrying out unsupported printing, eliminating splashing and the like. Compared with the traditional additive manufacturing equipment with single laser, double laser, four laser or even more laser quantity, the printing of the outer area has great improvement in the aspects of cost, system complexity, construction speed and the like.
3) The Gaussian beam is modulated into the Bessel beam by the SLM, the problem that the heat deposition mode around the material cannot be controlled by the Gaussian beam on the printing working surface can be effectively solved, the energy of the center of a light spot is dispersed to the periphery through phase modulation, the thermal profile and microstructure grains are optimized, and the surface quality and the tissue performance of a formed workpiece are further improved.
4) On the premise of not influencing a printing light path system, a laser beam of a printing working face is reflected to a monitoring light path through a spectroscope, a beam signal is received through a detector to monitor the working state of a processing face, the working state of the processing face is analyzed and then can be fed back to a laser through a control system, and optical parameters of the laser are adjusted in real time, so that higher processing and forming quality is obtained.
The foregoing description is only illustrative of the present invention and is not intended to limit the scope of the invention, and all equivalent structures or equivalent processes or direct or indirect application in other related technical fields are included in the scope of the present invention.
Claims (9)
1. The surface area printing system for laser additive manufacturing is characterized by comprising a green laser and a laser working module, wherein the laser working module comprises a reflecting mirror, a beam shaping module, a light homogenizing sheet, a phase modulation module, pattern indicating light, a first spectroscope, an optically addressable light valve, a polarizing beam splitter, a second spectroscope and a scanning system;
The green laser emits laser beams, the laser beam transmission direction is changed through a reflecting mirror, the laser beams are shaped into square light spots through a beam shaping module, the square light spots are uniformly processed through a light homogenizing sheet, the uniformly processed laser beams enter a phase modulation module to be subjected to phase modulation, the laser beams after phase modulation and the light beams emitted by pattern indication light are transmitted to an optical addressable light valve through a first spectroscope together, the optical addressable light valve carries out patterned deflection modulation on mixed laser beams, S polarized light beams in the modulated laser beams are reflected to a beam collector through a polarization beam splitter, P polarized light beams in the laser beams are transmitted to a second spectroscope through the polarization beam splitter, and the light beam deflection enters a working face through a scanning system to carry out laser material increase processing.
2. The area-of-area printing system for laser additive manufacturing of claim 1 wherein the beam shaping module comprises a vertically disposed cylindrical lens and a laterally disposed cylindrical lens, the laser beam passing through the vertically disposed cylindrical lens before passing through the laterally disposed cylindrical lens.
3. The area-of-surface printing system for laser additive manufacturing of claim 1, wherein the phase modulation module comprises a first wave plate, a polarizer, an SLM, and a second wave plate; the first wave plate and the polarizer modulate the laser beam, then the SLM is utilized to modulate the Gaussian beam into a Bessel beam, and the Bessel beam enters the second wave plate for phase compensation.
4. The area-of-area printing system for laser additive manufacturing of claim 3, wherein the initial laser beam polarization state of the green laser is horizontal polarization, and the modulation formula adopted by the phase modulation module is:
S out1 represents the Stokes vector of the emergent light beam after passing through the first wave plate, M p1 represents the Mueller matrix of the first wave plate, S in represents the Stokes vector of the polarization state of the light beam, and the output of the laser is circularly polarized light after the horizontal polarized light is outputted by the laser and modulated by the first wave plate according to the formula (1);
S out2 represents the Stokes vector of the outgoing beam after passing through the polarizer, M q represents the Mueller matrix of the polarizer, and the circularly polarized light obtained by the formula (2) is output as extraordinary light after being modulated by the polarizer.
5. The area-of-area printing system for laser additive manufacturing of claim 1, wherein the phase modulation module comprises a polarizer, an SLM, and a second waveplate; the polarizer modulates the laser beam, then the SLM modulates the Gaussian beam into a Bessel beam, and the Bessel beam enters the second wave plate for phase compensation.
6. The area-of-surface printing system for laser additive manufacturing of claim 5 wherein the green laser initial laser beam polarization state is circular polarization, and the phase modulation module employs a modulation formula:
s out3 represents the Stokes vector of the emergent light beam after passing through the second wave plate, M p2 represents the Mueller matrix of the second wave plate, S out2 represents the Stokes vector of the emergent light beam after passing through the polarizer, and the extraordinary light is obtained by the formula (3) and is output as horizontally polarized light after being modulated by the second wave plate.
7. The area-of-area printing system for laser additive manufacturing of claim 1, wherein the pattern indicates that the beam of light emitted is 450nm.
8. The area-of-surface printing system for laser additive manufacturing of claim 1, further comprising an attenuation sheet, an optical filter, and a detector; and part of light reflected by the working surface is transmitted into the attenuation sheet and the optical filter through the second beam splitter and then received by the detector.
9. A face area printing system for laser additive manufacturing according to claim 8, wherein the detector is a PD or a CCD for power and image monitoring of the printed working face.
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CN202410022105.0A CN117884656A (en) | 2024-01-08 | 2024-01-08 | A face region print system for laser material increase makes |
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