JP2022503614A - Stacked modeling system with an array of addressable lasers and real-time feedback control of each light source - Google Patents

Abstract

An assembly is provided for coupling a group of laser sources to a coupled laser beam. Further provided is a blue diode laser array that couples a laser beam from a blue laser diode. Laser machining operations and applications using a coupled blue laser beam from an array of laser diodes and modules are provided.
[Selection diagram] Fig. 1

Description

This application is based on (i) Article 35 §119 (e) (1) of the US Patent Act, and the benefits and priorities of the filing date of US provisional application No. 62 / 726,234 filed on September 1, 2018. Claim the interests of the right and the entire disclosure is incorporated herein by reference.

The present invention relates to an array assembly for coupling laser beams, especially for use in systems and applications in the fields of manufacturing, production, entertainment, graphics, video, analysis, surveillance, assembly, dentistry, and medical. With respect to an array assembly capable of providing a high intensity laser beam.

Many lasers, especially semiconductor lasers such as laser diodes, provide laser beams with highly desirable wavelengths and beam qualities, including brightness. Such lasers have wavelengths in the visible region, UV region, IR region, and combinations thereof, as well as higher or lower wavelengths. The technology of semiconductor lasers and other laser light sources, such as fiber lasers, is rapidly evolving with the continuous development of new laser light sources to provide existing and new laser wavelengths. Many of these lasers have the desired beam quality, but have a lower laser power than the one desired or required for a particular application. Therefore, the low power has prevented these laser light sources from finding great practical and commercial applications.

In addition, traditional efforts to combine these types of lasers include, to name a few, the difficulty of beam alignment, the difficulty of keeping the beam aligned during use, and the beam quality. It was generally inadequate because of degradation, difficulty in specific placement of the laser source, size considerations, and power control.

Infrared (IR) -based stacked modeling systems using galvanometer scanners (eg, having wavelengths greater than 700 nm, especially wavelengths greater than 1,000 nm) have two disadvantages: build volume and build speed, among others. Has the disadvantage of being restricted. In such an IR laser system, the build volume is limited by the limit size of the scanning system, as well as the spots created for the collimated and fθ lenses of a given focal length. For example, when a collimated lens having a focal length of 140 mm and an fθ lens having a focal length of 500 mm are used, the spot size for a 1 μm laser is about 40 μm for a diffraction-limited single-mode laser. This provides an addressable footprint of approximately 175 mm x 175 mm on the powder layer, which limits the size of the part that can be modeled. The second limitation on build speed in IR laser systems is the absorption of the laser beam by the powder material. Most raw materials have moderate to high reflectivity for wavelengths in the infrared spectrum. As a result, the binding of infrared laser energy to the powder layer is limited, with a significant portion of that energy reflected away from or behind the powder layer or deeper into the powder layer. These limitations are further associated or combined together to exacerbate the problems and shortcomings of IR laminated systems. Thus, the finite penetration depth of infrared light determines the optimum layer thickness and, as a result, limits the resolution and process speed. The shortcomings of these and other IR-based manufacturing and modeling systems and processes have not been adequately addressed. Therefore, the long-standing demand for improvements in laminated modeling systems and processes has not been met.

As used herein, unless otherwise stated, the terms "blue laser beam", "blue laser", and "blue" should be given the broadest meaning and are generally laser beams, laser beams, lasers. Refer to a system that provides a light source, eg, a laser beam or light having a wavelength of 400 nm to 500 nm and a wavelength of about 400 nm to about 500 nm, and provides a laser and a diode laser that propagates, for example. The blue laser includes wavelengths of 450 nm, about 450 nm, 460 nm, and about 460 nm. Blue lasers can have bandwidths from about 10 pm to about 10 nm, about 5 nm, about 10 nm, and about 20 nm, as well as larger and similar values.

As used herein, unless otherwise stated, "UV", "ultraviolet", "UV spectrum", "UV portion of spectrum", and similar terms should be given the broadest meaning and are about. Includes light with wavelengths from 10 nm to about 400 nm and from 10 nm to 400 nm.

As used herein, unless otherwise stated, the terms "visible", "visible spectrum", "visible portion of spectrum", and similar terms should be given the broadest meaning, from about 380 nm to about. Includes light with wavelengths of 750 nm and 400 nm to 700 nm.

As used herein, unless otherwise stated, the terms "green laser beam", "green laser", and "green" should be given the broadest meaning and are generally laser beams, laser beams, lasers. Reference is made to a system that provides a light source, eg, a laser beam or light having a wavelength in the range of 500 nm to 700 nm and about 500 nm to about 700 nm, providing, for example, propagating, a laser and a diode laser. The green laser includes wavelengths of 515 nm, about 515 nm, 550 nm and about 550 nm. Green lasers can have bandwidths from about 10 pm to about 10 nm, about 5 nm, about 10 nm, and about 20 nm, as well as larger and similar values.

In general, as used herein, the terms "about" and the symbol "~" are, unless otherwise specified, a ± 10% change or range, an experimental or instrumental error associated with obtaining the above values. , And preferably include those larger changes or ranges.

As used herein, room temperature is 25 ° C., unless otherwise stated. The standard environmental temperature and standard environmental pressure are 25 ° C. and 1 atm. Unless otherwise stated, all tests, test results, physical properties, and temperature-dependent, pressure-dependent, or both-dependent values are given at standard environmental temperature and standard environmental pressure. Can also include viscosity.

As used herein, unless otherwise stated, the enumeration of a range of values here merely serves as an easy way to individually reference each separate value contained within that range. be. Unless otherwise specified herein, each individual value within the range is incorporated herein as if they were individually listed herein.

Typically, the conventional method employed in laminated molding is an infrared laser, and a laser beam, across the surface of the powder layer in a welding process that melts the liquefied powder and fuses it to the underlying layer or base. Use a galvanometer for scanning. This approach has some limitations that determine the speed of machining. For example, a single laser beam is used to scan the surface and the build speed is limited by the galvanometer's maximum scan speed (7 m / sec). Manufacturers have sought to take advantage of IR technology and believe that it is typically the only visible wavelength, so by incorporating two or more IR lasers / galvanometers into the system, the two work together. We strive to overcome this limitation by allowing one part to be modeled or working independently to form multiple parts in parallel, but with limited success. do not have. While these efforts are aimed at improving the processing power of the laminated build system, they have been focused exclusively on IR, with limited success and meeting the long-standing demand for improved laminated build. do not have.

Another example of the limitation in the IR process is the high intensity of the laser spot that forces the system into a keyhole welding mode that spatters and creates voids in the part. For example, when using a 500 mm fθ lens, the IR laser produces a spot size of 40-50 μm with respect to the diffraction limited infrared laser. When the laser beam is operating at a light output of 100 watts, the intensity of the beam is greater than the intensity required to initiate the keyhole welding mode. The keyhole welding mode gives rise to a plume of evaporated material, which must be removed out of the path of the laser beam by a cross jet, otherwise the laser beam is scattered and absorbed by the evaporated metal. Also, in the keyhole mode of welding, a hole is formed on the surface of the liquid metal, and the hole is maintained by the vapor pressure of the evaporated metal, so that the evaporated metal is discharged from the keyhole. This material is called spatter and results in the melted material depositing elsewhere on the build plane, which can cause defects in the final product. Manufacturers of laminated build systems have had limited success in developing rapid prototyping equipment to meet long-standing demand and meet the requirements needed to manufacture commercial or actual parts. Not done. Achieving this requires breakthroughs in the method of patterning parts that have not been achieved prior to the present invention.

In general, problems and drawbacks with IR processes and systems are the requirements or requirements for fusing powders in keyhole welding mode. This is typically due to the use of a single beam for processing the powder. When the laser beam is operating at a light output of 100 watts, the intensity of the beam is greater than the intensity required to initiate the keyhole welding mode. The keyhole welding mode gives rise to a plume of evaporated material, which must be removed out of the path of the laser beam by a cross jet, otherwise the laser beam is scattered and absorbed by the evaporated metal. Also, the keyhole mode of welding forms holes in the surface of the liquid metal, which are maintained by the vapor pressure of the evaporated metal, so that materials such as evaporated metal are discharged from the keyholes. This material is called spatter and results in the melted material depositing elsewhere on the build plane, which can cause defects in the final product.

A recent study by the Lawrence Livermore National Laboratories using an Optically Activated Light Valve (OALV) attempted to address these IR limitations. rice field. OALV is a high power spatial light modulator used to generate light patterns using a high power laser. The pattern on the OALV is produced by a blue LED or laser light source from the projector, and the output from the four laser diode arrays is transmitted via a spatial light modulator and used to heat the image to its melting point, keyholes. A Q-switched IR laser is required to initiate welding. IR lasers are used to initiate welding in keyhole mode and are required for these materials, especially when fusing copper or aluminum materials. This keyhole welding process can cause spatter and voids in the part, as well as large surface roughness. This keyhole welding process usually results in spatter, voids in the part, and large surface roughness. Therefore, the OALV system, like a typical IR system, does not eliminate the side effect of keyhole initiation in the modeling process. It is good to avoid the keyhole welding step altogether, but the technology has not been able to overcome this problem and has not provided this solution. This drawback is primarily due to the very low absorption properties of many metals at IR wavelengths and the need for high peak power lasers to initiate the process. Since OALV is transparent only in the IR region of the spectrum, it is not appropriate to build or use this type of system using a visible laser light source as a high energy light source. The cost of the components of this system, especially the custom component OALV, is very high.

Conventional metal-based laminated molding equipment sprays a binder into the powder layer and then performs a consolidation step at high temperature, or scans the powder layer at high speed with a high power single mode laser beam by a galvanometer system. , Is very limited in that it is based on either. Both of these systems have significant drawbacks that the technology could not overcome. The former system allows mass production of parts, but it has large tolerances due to the shrinkage of parts during the consolidation process. In the latter process, the build speed is limited by the galvanometer scan speed, which limits the maximum power level laser that can be used, resulting in a limited build speed. Manufacturers of scan-based stacked build systems have sought to overcome this limitation by building equipment with multiple scan heads and laser systems, but this has not provided a suitable solution to these problems. .. This does increase throughput, but the scaling law is linear, in other words, can a system with two laser scanners only form twice as many parts as a system with one scanner? , Or only one part can be modeled at twice the speed. Therefore, there is a need for a high throughput laser-based metal laminate modeling system that does not suffer from the limitations of existing systems.

The background art is intended to introduce various aspects of the technology that may be relevant to embodiments of the present invention. Therefore, the above description in this section provides a framework for a better understanding of the invention and should not be considered as an approval of the prior art.

In particular, there are long-standing unmet requirements for assemblies and systems for combining multiple laser beam sources into a single or multiple laser beams while maintaining and improving beam quality such as desired brightness and output. .. The invention of the present application solves these requirements, among other things, by providing a description of the articles, devices, and processes taught and disclosed herein.

One embodiment of the present invention has the ability to step and repeat using a precision gantry system (FIGS. 1, 2, 3) and is a 1-D or 1-D laser beam capable of directly fusing powders in parallel. It is a laminated modeling system based on a 2-D array. The speed can be increased by adding a 1-D or 2-D auxiliary laser beam to control preheating and cooling (FIG. 4). The auxiliary laser can also be an addressable array of laser beams to provide a preheating pattern that matches the pattern to be modeled.

Another element of the embodiment of the invention is the use of a real-time temperature monitoring camera such as a thermal detection camera. The camera can be used to monitor the temperature of the powder layer in real time during the phase transition from solid to liquid, and the image on the camera can be corrected with the laser pattern applied, individually. The output level of the laser beam can be adjusted according to certain requirements to provide proper fusion and cooling of the printed parts. This closed loop control of temperature provides additional advantages such as minimizing voids in manufactured parts, optimizing surface roughness, and minimizing residual stress in parts.

One embodiment of the invention includes means for depositing powder in either direction in real time during the printing process and further squeezing the powder layer to minimize voids in the powder layer. The main process for melting and fusing powders will be conduction mode welding for galvanometer scan systems where keyhole mode welding is utilized. This technique minimizes spatter and also minimizes the need to protect the optics of windows and manufactured components.

In one embodiment, the invention includes a sealed enclosure for forming an oxygen-free environment and a recirculation system for the gas that continuously cleans the gas mixture used. Airborne powder and weld fume, if not removed from the environment, will begin to affect the quality of the image and will affect the quality of the resulting parts, so filtering of the gas mixture is necessary.

In one embodiment, the invention includes a microprocessing system that performs prior modeling analysis, division of parts into flakes, and determination of optimal modeling plans. When each part of the pattern of a part is printed, the gantry system moves to the next adjacent part of the pattern, or the sculpting plan randomizes the partial pattern to minimize residual stress in the part. If you are requesting a print, you will be instructed to move to any position.

In one embodiment, the invention will also not require a weld monitor other than a mere visible camera to find metal pools in the weld. Since there is no keyhole welding mode, the metal pool in the weld is very stable even when welding copper and aluminum, which is not possible with IR laser light sources. In order to capture the exact appearance of keyholes and how the shaping of parts is progressing due to the unstable nature of keyhole modes, the IR laser source is an optical coherence tomography (OCT) scanner. I have to rely on such a welding monitor. The conduction mode in which the powder is welded to the base material is a very stable welding mode, so no spatter occurs, the welded powder is very uniform in thickness and shape, and the density of the parts is that of the material of the welding process. 100% due to lack of evaporation.

Thus, a laminated modeling system, process, and laser system having one or more of the features described above is provided. Also provided are laser systems, as well as laminated modeling systems, processes and laser systems that have one or more of the above features in combination with the following laser systems and methods.

Thus, it provides a laser system for performing laser operation, the system being: multiple laser diode assemblies; each laser diode assembly can generate a separate blue laser beam along the laser beam path. With multiple laser diode assemblies with multiple laser diodes; separate blue laser beams to create a combined laser beam with a single spot in the distant field that can be coupled to the optical fiber for delivery to the target material. With means for spatially coupling; the means for spatially coupling individual blue laser beams on the laser beam path are optically associated with each laser diode.

It also provides a method system with one or more of the following features: having at least three laser diode assemblies; each laser diode assembly having at least one laser diode; the laser diode assembly having a total output of at least about 2 watts. And can propagate a laser beam with a beam parameter characteristic of less than 20 mm mrad; the beam parameter characteristic is less than 15 mm mrad; the beam parameter characteristic is less than 10 mm mrad; because of spatial coupling. Means generate a coupled laser beam with an output density N times that of the individual laser beams; N is the number of laser diodes in the laser diode assembly; the means for spatially coupling is the brightness of the coupled laser beam. Increase the output of the laser beam while preserving; the combined laser beam has an output of at least 50 times the output of the individual laser beams so that the beam parameter product of the combined laser beam is the beam parameters of the individual laser beams. Not greater than N times the product; the beam parameter product of the combined laser beam is not greater than 1.5 x N times the beam parameter product of the individual laser beams; the beam parameter product of the combined laser beam is the individual lasers. Not greater than 1 × N times the beam parameter product of the beam; means for spatially coupled to increase the output density of the combined laser beam while preserving the brightness of the individual laser beams; It has an output density that is at least 100 times the output of the laser beam, so that the beam parameter product of the combined laser beam is not greater than 2 x N times the beam parameter product of the individual laser beams; the beam parameter product of the combined laser beam. Is not greater than 1.5 × N times the beam parameter product of the individual laser beams; the beam parameter product of the combined laser beam is not greater than 1 × N times the beam parameter product of the individual laser beams; optical fiber. Is solarization resistant; the means for spatial coupling is selected from the group consisting of aligned plane parallel plates and wedges to compensate for at least one of the laser diode positional errors or laser diode pointing errors. It has an optical assembly; the means for spatially coupling the effective brightness of the coupled laser beam individually. It is a polarized beam coupler that can be increased more than the laser beam of the Has a space between each beam; the means for spatially coupling is a collimator for collimating the individual laser beams to the fast axis of the laser diode and a period for coupling the collimated laser beams. The periodic mirror has such that the first laser beam from the first diode in the laser diode assembly is reflected and the second laser beam from the second diode in the laser diode assembly is transmitted. The space in the first direction between the individual laser beams is filled; the means for spatially coupling has a patterned mirror on the glass substrate; the glass substrate is between the laser diodes. It is thick enough to move the vertical position of the laser beam from the laser diode to fill the empty space of the; it has a stepped heat sink.

Furthermore, it provides a laser system that provides a high-intensity, high-power laser beam, which is: multiple laser diode assemblies; each laser diode assembly can generate a blue laser beam with initial brightness. With multiple laser diode assemblies with multiple laser diodes; spatially coupled blue laser beams to create a coupled laser beam that has final brightness and forms spots in the far field that are coupled within a single optical fiber. Each laser diode is locked to a different wavelength by the external cavity, which greatly increases the brightness of the coupled laser beam and the final brightness of the combined laser beam is the laser from a single laser diode. It is about the same as the initial brightness of the beam.

It also provides methods and systems with at least one of the following features: each laser diode is locked to a single wavelength using an external cavity based on a diffraction grid, and each of the laser diode assemblies is closely spaced. It is coupled to the coupled beam using a coupling means selected from the group consisting of optical filters and diffractive grids; An optical fiber with an outer core surrounded by either air or a low molecular weight polymer containing blue pump light; a Raman converter is like an optical fiber having a GeO ₂ doped central core with the outer core. Used to pump a Raman converter to create a brighter light source, the outer core is larger than the central core to include blue pump light; the Raman converter is used to create a higher brightness light source. An optical fiber with a _P2O5 doped core and an outer core that is larger _than the central core to contain the blue pump light; the Raman converter is a refraction to create a higher brightness light source. An optical fiber having a rate distribution core and an outer core that is larger than the central core and contains blue pump light; the Raman converter is a refractive index GeO ₂ doped core and outer step. The type core; the Raman converter is used to pump the raman converter fiber, which is a refractive index distributed _{P2O5 doped} core and an outer stepped core; the Raman converter. The Raman converter fiber, which is a refractive index distributed GeO ₂ doped core, is used to pump; the Raman converter is a refractive index distributed P ₂ O ₅ doped core and outer step type. The core; the Raman converter is a diamond for producing a higher brightness laser light source; the Raman converter is a KGW for producing a higher brightness laser light source; the Raman converter is a higher brightness. The Raman converter is Ba _{(NO 3) 2 for producing} a higher brightness laser light source; the Raman converter is for producing a higher brightness laser light source. High pressure gas.

Furthermore, it provides a laser system for performing laser operation, which is: multiple laser diode assemblies; each laser diode assembly can generate a blue laser beam along the laser beam path. With multiple laser diode assemblies, which have a laser diode in the With means for spatially coupling the blue laser beam, to increase.

In addition, it provides a method of providing a coupled laser beam, which produces a blue laser beam at different wavelengths individually and combines the laser beams to achieve higher output while preserving the spatial brightness of the original light source. It has an array of Raman conversion lasers to create a light source.

Furthermore, it provides a laser system for performing laser operation, which is: multiple laser diode assemblies; each laser diode assembly can generate a blue laser beam along the laser beam path. With multiple laser diode assemblies having multiple laser diodes; with beam collimating and beam coupling optics that are located along the laser beam path and can provide coupled laser beams; optical fibers that receive the coupled laser beam. And have.

It also provides a method and system having one or more of the following features: an optical fiber is optically communicated with a fiber doped with a rare earth element so that the combined laser beam is doped with a rare earth element. Fibers can be pumped to create a brighter laser source; the optical fiber is optically communicated with the outer core of the brightness converter, and the coupled laser beam pumps the outer core of the brightness converter. A greater proportion of brightness increase can occur.

Furthermore, it also provides a Raman fiber, which is: a dual core and one of the dual cores is a high-intensity central core, with a dual core; with a filter, a fiber Bragg diffraction grating, and a primary Raman signal. High-brightness central core selected from the group consisting of differences in V number for the secondary Raman signal, differences in fiber length or reciprocating gain for the primary Raman signal due to the cavity mirror, and differences in microbend loss. With means for suppressing the secondary Raman signal.

In addition, it provides a second harmonic generation system, which is a Raman converter at the first wavelength, which produces light in a non-linear crystal at half the wavelength of the first wavelength. And; it has an externally incorporated doubling crystal that is designed to prevent half-wavelength light from propagating through the optical fiber.

Further, a method and system having one or more of the following features are provided: the first wavelength is about 460 nm; the external resonant doubled crystal is KTP; as the Raman transducer improves Raman conversion efficiency. It has a constructed non-circular outer core.

In addition, it provides a third harmonic generation system, which is: a Raman converter at the first wavelength, with a Raman converter that produces light at a second wavelength smaller than the first wavelength; It has an external resonant doubled crystal designed to prevent wavelengths of lower wavelengths from propagating through the optical fiber.

In addition, it provides a fourth harmonic generation system, which uses an external resonant doubled crystal designed to prevent light at a wavelength of 57.5 nm from propagating through optical fibers at 57.5 nm. Has a Raman converter to generate light in.

In addition, it provides a second harmonic generation system, which has a rare earth element-doped brightness converter with a turium that emits a laser at 473 nm when pumped by an array of 450 nm blue laser diodes. However, an external resonant doubled crystal is used to generate light at half the wavelength of the light source laser, 236.5 nm, but prevent light of that short wavelength from propagating through the optical fiber.

In addition, it provides a third harmonic generation system, which has a rare earth element-doped brightness converter with a turium that emits a laser at 473 nm when pumped by an array of blue laser diodes at 450 nm. Then, an external resonance doubled crystal is used to generate light at 118.25 nm, but the short wavelength light is prevented from propagating through the optical fiber.

In addition, it provides a fourth harmonic generation system, which has a rare earth element-doped brightness converter with a turium that emits a laser at 473 nm when pumped by an array of blue laser diodes at 450 nm. An external resonant doubled crystal is used to generate light at 59.1 nm, but the short wavelength light is prevented from propagating through the optical fiber.

In addition, it provides a laser system for performing laser operation, which is: at least 3 laser diode assemblies; each of the at least 3 laser diode assemblies has at least 10 laser diodes. Each of the at least 10 laser diodes can produce a blue laser beam with an output of at least about 2 watts and a beam parameter product of less than 8 mm mad along the laser beam path, with each laser beam path substantially. With at least 3 laser diode assemblies that are parallel and thereby demarcate space between the laser beams propagating along the laser beam path; placed on all of at least 30 laser beam paths. Also, a means for spatially coupling a blue laser beam to maintain its brightness, a collimating optical element for the first axis of the laser beam, a vertical prism for the second axis of the laser beam. The means for spatially coupled and retaining the brightness, including the array and the telescope; the means for spatially coupling and retaining fill the space between the laser beams with laser energy. It provides a coupled laser beam with an output of at least about 600 watts and a beam parameter product of less than 44 mm mrad.

Further further, it provides an addressable array laser processing system, which has at least 3 laser systems of the type currently described; each of the at least 3 laser systems is IR coupled. The laser beam is coupled within a single optical fiber; thereby propagating each of at least three coupled laser beams along the coupled optical fiber; at least three optical fibers are optical with the laser head. Associated with; the system further comprises a control system; the control system has a program having a predetermined sequence for delivering each of the coupled laser beams to a predetermined location on the target material.

It also provides methods and systems for addressable arrays with one or more of the following features: the laser beam from the laser head is individually switched on and off, thereby binding onto a layer of powder. , A predetermined sequence for melting a target material with powder and fusing it into a part; the fibers of the laser head are arranged in an array selected from the group consisting of linear, non-linear, circular, diamond, square, triangular, and hexagonal. The fibers of the laser head are arranged in a sequence selected from the group consisting of 2x5, 5x2, 4x5, at least 5x, at least 5, 10x5, 5x10, and 3x4. The target material has a powder layer; the laser head can be moved across the powder layer, thereby having an xy transfer system that melts and fuses the powder layer; moves behind the laser light source and renews. It has a powder supply system that feeds after the fused layer of the powder layer; it has a z-movement system that moves the laser head to increase and decrease the height of the laser head over the surface of the powder layer; positive x It has a bidirectional powder placement device that can travel in a directional or negative x direction and place the powder directly after the delivered laser beam; it has a powder supply system that is coaxial with multiple laser beam paths; gravity. It has a feed powder system; it has a powder supply system, the powder is accompanied by an inert gas stream; it has a powder supply system across N laser beams, where N ≧ 1, and the powder is gravity. Placed in front of the laser beam by; having a powder supply system across N laser beams, where N ≧ 1, the powder is entrained in an inert gas stream that intersects the laser beam.

Furthermore, we also provide a method of providing a coupled blue laser beam with high brightness, which methods: manipulating multiple Raman conversion lasers to provide multiple individual blue laser beams, and individual blue laser beams. To create a light source with a higher output while preserving the spatial brightness of the original light source; the individual laser beams of the plurality have different wavelengths.

It also provides a method of laser processing the target material, which method is at least three laser systems of the type of system described herein for generating three separate coupled laser beams within three separate optical fibers. Has an addressable array laser processing system with; propagates each coupled laser beam along its optical fiber to the laser head; three individual coupled laser beams from the laser head on the target material in a predetermined sequence. Aim in place.

It is a perspective view of the embodiment of the 3-D printer based on the fiber array which concerns on this invention.

It is a perspective view of the embodiment of the fiber-based printer head which concerns on this invention.

2A is a perspective view of the fiber-based printer head of FIG. 2A from different viewpoints.

It is a schematic diagram of the embodiment of the bundle of light and the beam path which concerns on this invention.

FIG. 3 is a perspective view of an embodiment of a 1-D bundle connector output for a fiber bundle for a 1-D patterning system according to the present invention.

It is a perspective view of the embodiment of the fiber coupler which concerns on this invention.

FIG. 3 is a schematic diagram of an embodiment of a 3-D printer head including an auxiliary laser heating light source and a main 1-D patterning system according to the present invention.

It is a perspective view of the embodiment of the image in which the auxiliary laser pattern and the main image of the multi-spot overlap each other according to the present invention.

FIG. 3 is a schematic diagram of an embodiment of a 3-D printer head including an auxiliary laser heating light source and a main 1-D patterning system according to the present invention.

It is a perspective view of the embodiment of the image in which the auxiliary laser pattern and the main image of a multi-spot overlap each other according to the present invention.

It is a schematic diagram of the embodiment of the printer head which has the main multi-spot image of 1-D and the auxiliary heating image based on the laser diode array for the main image which concerns on this invention.

It is a perspective view of the embodiment of the image in which the auxiliary laser pattern and the main image of a multi-spot overlap each other according to the present invention.

It is a plan view of various embodiments of the image composition (for example, a laser beam forming a laser beam pattern, or a laser pattern) of a fiber bundle on a powder layer according to the present invention, and the arrow indicates the movement of the pattern on the layer. It shows the direction.

It is a plan view of various embodiments of the image composition (for example, the laser beam forming a laser beam pattern, or the laser pattern) of the fiber bundle on the powder layer which concerns on this invention, and the main laser beam image is an auxiliary laser beam image. Associated with, the arrows indicate the direction of movement of both patterns on the layer. (The main image spot is indicated by a solid spot, and the auxiliary image spot is indicated by a contour spot.)

It is a top view of various embodiments of the image composition (for example, the laser beam forming a laser beam pattern, or the laser pattern) of the fiber bundle on the powder layer which concerns on this invention, and the main laser beam image is an auxiliary laser beam image. Associated, the auxiliary laser beam images have different timing features that produce differently shaped auxiliary images, and the arrows indicate the direction of movement of both patterns on the layer.

It is a schematic plan view of the mapping of the image on the powder layer on the heat detection camera which concerns on this invention.

It is a schematic diagram of the embodiment of the control system and the closed loop control process which concerns on this invention.

It is a spectrum of an image and a blue Raman conversion laser beam which concerns on this invention.

The present invention relates to laser processing of materials, particularly laser modeling of materials, comprising a laser laminated modeling process using a laser beam having a wavelength of about 350 nm to 700 nm.

1-D patterning system

FIG. 1 is a perspective view of a 3-D (three-dimensional) laminated modeling device or a printer device 100. The printer device 100 has a fiber structure input into the printer head, which is a 1-D (one-dimensional) fiber structure. The 1-D system can have input fibers arranged linearly, eg, as shown in FIGS. 2A and 2B, and also have ray paths, images, and optics, eg, as shown in FIG. ..

Figure 1-3 is an example of a 3-D printer using a 1-D patterning system, where 1-D is a bundle of fibers that provides and emits a laser beam used to shape a 3-D object. Refers to the structure.

First, with reference to FIG. 1, in light of FIGS. 2A, 2B, and 3, the system 100 includes an xy gantry system 101 that moves the printer head 200 in the x and y directions. The gantry system is mounted on a base 112 made of granite, metal, or other material of choice that is heavy and stable. The base is vibrationally insulated from the rest of the system using rubber or air supports beneath it to prevent vibration transmission from the base to the powder layer 110 and the printer head 200. The entire system 100 is enclosed in an airtight environment (not shown) to provide an inert atmosphere for powder processing. The inert atmosphere can be an inert gas other than argon, nitrogen, helium, or oxygen. The inert atmosphere can be a reduced pressure, an atmospheric pressure, or an increased pressure, and there is a flow through (inflow port and outflow port), there is an inflow (replenishment gas flows in but does not flow out). ) Or no flow (the input and output sections are closed after filling with the inert gas). In a preferred embodiment, it is an argon and argon-CO2 mixed gas to promote the flow of the molten powder by breaking their surface tension. The stage of the gantry carries the printer head 200, and the bundle of fiber arrays is sent to the printer head 200 by the QBH type connector 102. Immediately below the printer head is a powder layer 110, and the image transmitted by the fiber bundle or array is reimaged 103 on the powder layer 110. The powder is diffused by a bidirectional powder diffuser 108 resting on a pair of straight rails 109 for precision movement. The powder diffuser is driven by the y-direction movement of the Y-moving stage 106 of the gantry system 101 or by another motor built into the powder diffuser assembly. The powder is filled in the powder diffuser at the front and rear edges of the base 112, and the powder is fed to the powder layer by gravity feed. The powder diffuser includes a roller 107 that rotates in the opposite direction of its movement to spread and squeeze the powder layer. By squeezing the powder layer, voids in the final part can be minimized. Outputs and sensor reads are sent through a flexible cable tray 105 on the side of the gantry as the gantry moves in the y direction.

The gantry system 101 has a Y moving stage 106 for moving the printer head 220 in the y direction, and a Z moving stage 111 for moving the printer head 220 in the x direction. The system 100 has a powder layer elevator 104 (for moving the part downward so that the next layer is deposited on the part when it is modeled).

Preferred embodiments of the printer head 200 are shown in FIGS. 2A and 2B. It is understood that FIGS. 2A and 2B are perspective views of the same embodiment but from different perspectives, typically the printer head is covered, i.e. has a front plate (not shown). Fiber bundles are arranged linearly, preferably linearly, in 2, 3, 4, 5, 6, 2-10, and combinations thereof, as well as larger numbers. The fiber bundle is sent via the QBH connector 201. The QBH connector 201 is held in a predetermined position by a collet 202 attached to the case 203 of the printer head 200. The optical system includes a collimating optical element 204 and a condensing optical element 205. These two optical elements may be replaced with a single imaging optical element. The laser beam is emitted from the surface of the fiber 210 and travels along the laser beam path to the lens 204, the lens 205, and the exit window 209 to form the image 103. In addition to the optical system, the printer head 200 also houses a thermal detection camera or pyrometer camera 207 for monitoring the temperature of the molten pool on the powder layer through an opening or window 208 for the multispot image 103.

FIG. 3 outlines an embodiment of the 1-D optical system 300 and ray tracing of a laser beam path. The 1-D optical system can be used, for example, in the printer head 200. The fiber bundle 301 has five linearly arranged optical fibers 301a, 301b, 301c, 301d, 301e and provides an output laser beam along a beam path having a ray path 305, the output being collimated by a lens 302. Will be done. The lens 302 can be a plano-convex lens, a plano-convex aspherical lens, a pair of lenses, a triple lens, or a similar type of optical element. The collimated beam having the ray path 307 from the array bundle is then focused by the condenser lens 303 on the image 304 having a series of spots 304a, 304b, 304c, 304d, 304e. The condenser lens 303 can be an m, a plano-convex lens, a plano-convex aspherical lens, a pair of lenses, a triple lens, or an optical element of the same type. The size of the fiber is indicated by the scale 320 and the size of the image and the spot is indicated by the scale 321. The curved surfaces of the plano-convex lens and the plano-convex aspherical lens face each other to minimize spherical aberration in this system. The ray tracing shown in FIG. 3 is for a plano-convex aspherical lens of two fused quartz silicas. The spots are in the focal plane or the Fourier transform plane, and there is a slight spread of the image due to the small aberrations of the system, resulting in individual fiber images, ie spots 304a, 304b, 304c, 304d, which produce the image 304. 304e overlap. The system may also use a single imaging lens, where the exit plane of the fiber light source 301 is located at least 2f away from the imaging optical element and the image plane is at least 2f away from the optical element. This technique requires a much larger lens than the preferred embodiment, which uses a collimating lens and a condenser lens to reimage the fiber bundle. Preferably, a thermal detector or pyrometer camera monitors the temperature of the molten pool on the powder layer for each of the individual spots in the multispot image.

In the embodiment of the 1-D patterning system, the radiation part of the 1-D line, for example, the fiber surface is 2, 3, 4, ... n, which depends entirely on the physical size of the fiber and the QBH connector. .. In one embodiment, there is a single fiber. In one embodiment, 2 to 15, 2 to 10, 5 to 50, 2 to 1,000, 5 to 500, 100 to 2,000, more than 10, more than 20, more than 50, and combinations thereof. And variants, as well as more or fewer fibers, are arranged side by side, for example. Thus, for example, fibers with a diameter of 200 μm (eg, having a core diameter of about 10 to about 185 μm) can be used, and their beams and the beam image reimaged on the powder layer melt the powder. Provides output for fusion with the base material.

FIG. 4A shows a perspective view of an embodiment of the QBH type bundle connector output unit 700. The connector output section 700 has five fibers 701 arranged in a straight line and provides five emission sections of a laser beam, and images thereof, for example, circular spots. The connector output section 700 has a mechanical QBH input section 702 that houses five fibers. The input unit 702 can be plugged into, for example, a printer head, or, for example, a coupling assembly of the type shown in FIG. 4B. The connector output unit 700 has a protective cover 703 that covers the optical fiber and a destruction sensor.

An example of an embodiment of a fiber bundle coupler is shown in FIG. 4B. The coupler 806 in this case is a free space coupler comprising input fiber 801, 802, 803, 804, 805, and the input fiber is collimated and then coupled and refocused in the output fiber bundle 807. Then, it is transmitted by an optical fiber to, for example, an output connector or a printer head. The fiber bundle receives the output from each of the individual fibers 801, 802, 803, 804, 805 and is reimaged on the powder layer. The output from each fiber is about 2 watts (W), 10 W, 100 W, about 150 W, about 500 W, about 1 kW, about 2 kW, depending on, for example, how fast the gantry system scans and the size of the fiber bundle image. It can be from 1 W to about 2 kW, from about 2 W to about 150 W, from about 250 W to about 1 kW, or even a few watts, and combinations and variants thereof.

Examples of various embodiments of the 1-D fiber bundle structure and patterns of 1-D laser images generated by the printer head (eg, multispot images) are shown in FIGS. 8A, 8B, 8C, 8D, 8E, 8F. Has been done. The direction of movement of the pattern on the powder layer is indicated by an arrow. These laser patterns can be used with any embodiment of the laminated manufacturing system, printer head, and method according to the present invention.

The spots in a multi-spot image can be circular, oval, square, rectangular, and other shapes, which can be combined, adjacent, superposed, partially superposed; and more. Patterns that form large areas, such as squares or rectangles, can be linear, linear, curved, zigzag; their combinations and variants, as well as other configurations and arrangements. These laser patterns can be used with any embodiment of the laminated manufacturing system, printer head, and method according to the present invention.

The component is printed by scanning a 1-D image of the fiber bundle over the powder layer. The 1-D image with high power fiber output is scanned in the y-axis direction by the gantry system and stepped over in the x-axis direction to repeat the pattern. The stepover can be adjacent to the previously printed locus or can be randomly varied depending on the stress pattern desired for the final product. After printing, a powder layer elevator placed beneath the powder layer provides a predetermined amount of powder layer (eg, about 40 μm, about 50 μm, about 60 μm, about 35 μm to about 65 μm, and combinations thereof, and even larger or It is lowered by a small distance), the powder diffuser uniformly diffuses the layer of powder metal, and the roller compresses the powder layer to reduce the voids in the powder. When the powder layer is prepared for the next layer, an image of the 1-D fiber bundle is scanned over its surface and the next layer is printed.

The fiber system can also be replaced by a separate laser diode, but this is not a preferred embodiment due to the size of the printer head and the complex electronics required to drive the individual laser diode. The individual laser diodes can be part of the bar of an addressable laser diode array, in which case all the individual laser diodes are of a continuous bar assembly with individual current drive capability. It is a part. This is a good alternative to the fiber technique, which has a limited output per emitter.

1-D patterning system with auxiliary laser

In one embodiment, an additional or second laser beam is added to the printer head to provide means for preheating, cooling control, and temperature control of the printed image. Auxiliary laser beams are also called heating beams, while the main laser beams used to melt and fuse powders to form objects are called modeling lasers and modeling laser beams.

An embodiment of a printer head with a main laser beam and an auxiliary laser beam is shown in FIG. 5A, where the fiber bundles that provide the main laser beam to produce the main image 409 (which can be a multi-spot image) on the powder layer. , Delivered by the QBH connector 401 and mounted on the printer head 400 by the collet 402. The optical system for beam path and beam delivery for the main image 409 includes a lens 405 for collimating the output of the fiber bundle. The collimated output is condensed as a main image 409 on the output layer by the condenser lens 406. The optical system is similar to that described above, and the lens can be plano-convex, plano-convex aspherical, double or triple. The second laser beam is guided into the printer head 400 through an optical fiber delivered by a QBH connector 403 attached to the printer head at collet 404. The lens 407 is used to collimate the output of the fiber. The lens 407 can be plano-convex, plano-convex aspherical, double or triple. Most adhesives cannot withstand high power levels, so double or triple lenses must be air spaced at high power levels. The collimated beam is deformed by a lens or microlens system 408 that shapes the beam into an auxiliary image and redirects it to overlap the main image 409 and is focused on the powder layer. An embodiment of these overlapping images is shown in FIG. 5B. The overlapped image 450 is a main multi-spot image 451 having main spots 411, 412, 413, 414, 415, and the main spots are propagated from the main fibers of the main fiber bundle. The main spot is combined with the auxiliary image 410 of the auxiliary shaping laser beam. Preferably, the auxiliary image heats a volume of powder 420. In this embodiment, the auxiliary laser beam is arranged to store most of its energy immediately in front of the 1-D pattern 451 moved in the "y" direction indicated by arrow 416. Both the main pattern 451 and the auxiliary pattern 410 move in the same direction 416 at the same speed. This auxiliary beam pattern preheats the powder, helps the image of the fiber bundle melt the powder and fuses it to the substrate, and then anneals the material after fusion to reduce internal stress in the printed part. Supply some heat to do. The rest of the system functions as described above, and a thermal detection camera or pyrometer array is integrated into the system to bring the powder immediately in front of the image 451 of the main fiber bundle to a given temperature, preferably the powder. Provides feedback to the laser system to keep the temperature just below the melting point. During the fusion process, feedback signals from the thermal detector camera or pyrometer array control the output of the auxiliary laser, the individual lasers of the fiber bundle that produce the image 451 and both, within the image of the fiber bundle. Used to generate a given powder temperature. The predetermined powder temperature used in the system is initially determined experimentally in the system and used for all builds as a guideline for reducing surface roughness, porosity of parts, and part size. .. Auxiliary laser light sources are, for example, 50 watts, 100 watts, 150 watts, 500 watts, 1,000 watts, about 50 watts to about 2 kW, about, based on the scan speed of the printer head in use and the area of the fiber array pattern. It can range from 250 watts to about 1 kW, several watts, and all values within those ranges.

6A and 6B show perspective views of the laser head 500 that provides a combined image 509 of the auxiliary image 552 and the main image 551, with a powder layer having a heating pattern that can be addressed by the laser light sources of both auxiliary fiber bundles. Provided above. FIG. 6 illustrates the use of an auxiliary fiber bundle, which is attached by a connector 503 attached to the printer head 500 at the collet 504. The main fiber bundle is attached to the printer head 500 by a connector 501 and a collet 502, and has a collimating lens 505 and a Fourier transform condensing lens 506. The lens 507 collimates the fiber bundle and the beam shaping system 508 produces n images of the auxiliary fiber bundle that can be individually controlled to form the image 552, and in this embodiment the image 552 is heated. It has images 516, 517, 518, 519, 520 corresponding to the amount of powder in the powder layer. By controlling the time that each auxiliary laser light source is switched on and off, it is possible to change the preheating and cooling characteristics of the volume portions corresponding to images 516-520, respectively. In the embodiment of FIG. 5B, the two outer fibers providing the outer auxiliary images 516 and 520 are switched on and off at the same time to preheat the outer edge of the pattern. Since the heating of the two outer regions requires less energy in the inner regions, the two inner fibers providing images 517 and 519 are switched on slightly later and the heat generated from the outer fibers goes to the inner regions. Make it transmitted. Since the central auxiliary fiber image 518 requires even less energy, the light source can be switched on slowly and off slowly at lower output levels, depending on the thermal conductivity of the material and the design of the component. Heat is provided to anneal one region corresponding to the laser spot 513 or the entire region corresponding to the laser spots 511-515 forming the main multispot image 551. Each auxiliary fiber can be, for example, 30 watts, 100 watts, 150 watts, about 50 watts to about 2 kW, about 250 watts to about 1 kW, and several watts, depending on the scanning speed of the printer head and the size of the pattern being heated. The output, as well as the output of all values within these ranges, can be provided.

7A and 7B show a laser that provides a laser beam image 608 of a main multispot having spots 610, 611, 612, 613, 614 and an auxiliary laser beam image 609 that overlaps image 608 and heats a powder volume 651. A perspective view of the printer head 600 is shown. The main laser light source is a diode array 601 (which can provide a 1-D pattern or a 2-D pattern). The main laser beam path exits the array 601 and enters the first beam shaping optics 604 and then the second beam shaping optics 605 to produce an image 608, which is a 1-D pattern, on the surface of the powder layer. Form. The auxiliary laser has a fiber or fiber bundle connected to the printer head 600 by a connector 603 and a collet 603. The auxiliary laser beam path travels from the fiber or fiber bundle to the collimating lens 606 and then to the beam shaping optics 607 to form the auxiliary laser beam image 609 and superimpose it on the main laser beam image 608. The direction of travel of the laser beam and the corresponding image with respect to the powder layer is indicated by arrow 615.

In embodiments 7A and 7B, an addressable laser diode array light source provides an addressable heating pattern on the powder layer. Each emission from the addressable laser diode array light source 601 can be 3 watts, 10 watts, or greater, limited by diode array technology. Since the individual output levels of the laser diode are not sufficient to melt many metallic materials on their own, the auxiliary heating or laser light source provided within the connector 602 by the fiber or fiber bundle is an addressable laser. It is also required for its construction using diode arrays. Either a heated powder layer or an auxiliary laser source can be used. Here, an auxiliary laser source is used to provide image 609 to preheat the powder volume 651 to a temperature just below the melting point, and the image of the laser diode array 608 melts the powder and underneath it. Used to fuse with the material of. The auxiliary laser light source can be a single fiber or fiber bundle connected to the printer head 600 by a connector 602 and a collet 603, or the auxiliary laser light source is shown in a single image 609 or embodiment of FIG. 6A. It can be another laser diode array that is collimated and reimaged to form a series of images such as those shown above. A preferred embodiment of a laser diode array is a blue laser diode light source because it has improved absorbency for an IR laser diode light source. The 1-D pattern used in the direct laser diode array light source is most likely in the embodiments of FIGS. 8B and 8D, and the space between the diodes must be considered for any structure, but in FIGS. 8A-8A. To generate the image of any of the embodiments, an optical element that shapes the image can be used.

Whether one, more, or all of the main laser beams forming the main laser beam pattern are completely within the area of the auxiliary laser pattern, partially within the area of the auxiliary laser pattern, or a second laser beam. It can be completely outside the area of the pattern, and can be a combination and variant of these. In embodiments, the main laser beam pattern and the auxiliary laser beam pattern either move in the same direction at the same speed, or move in the same direction at different speeds (eg, faster for the main or faster for the auxiliary). It can move in a direction, move at the same or different speeds, and can be a combination and variant of these. The main laser beam and the auxiliary laser beam can also be moved in an independent predetermined pattern to form a specific type of item or provide a specific type of feature to the modeling item.

The main laser beam pattern can have one, two, three, four, or more, and ten or more laser beams. The auxiliary laser beam pattern can be a single beam, a plurality of laser beams, or a plurality of overlapping laser beams, and can be a combination and a modification thereof.

The cross section of the main laser beam can be circular, elliptical, square, or other shape. The main laser beam patterns are linear, square, rectangular, circular, elliptical, parabolic (convex or concave with respect to pattern movement), arcuate (convex or concave with respect to pattern movement), and arrows. Alternatively, they can be arranged in "V" arrangements, diamond arrangements, other geometric patterns and arrangements, as well as combinations and variants thereof.

In one embodiment, the auxiliary pattern is a high intensity visible, UV, or IR light imaged through a spatial light modulator, or a high power laser imaged through a spatial light modulator, or 1-D or 2. It can be an array of lasers with a range of 1 to N light sources arranged in a -D pattern. The array of auxiliary lasers can be an array of laser diodes or an array of fibers connected to a separate laser system.

2-D patterning system

A preferred embodiment uses a two-dimensional (2-D) fiber bundle or laser array as a heating or energy source when printing metal parts. Examples of some 2-D fiber bundles and laser patterns or multi-spot images that produce them are shown in the embodiment of FIG. 8D-8F. FIG. 8F is an image of a square spot, which is formed from an array of square or rectangular optical fibers, or other optical element that shapes the beam to provide such a spot. In one embodiment, the change from the 1-D patterning system to the 2-D patterning system embodiment is to add more rows of fibers to the printer head (comparing FIG. 8C to 8E), which is larger. Addressable areas add the ability to print faster. These 2-D light sources are 3 watts, 10 watts, 20 watts, 100 watts, 150 watts, about 50 watts to about 2 kW, about 250, depending on the scanning speed of the individual printer system and the size of the printed pattern. It can have a laser output level of about 1 kW from watts, and several watts.

The 2-D patterning system is combined with a single auxiliary laser light source, an array of auxiliary laser light sources, or a bundle of auxiliary laser light sources, as well as combinations and variants thereof, of energy or printed patterns for preheating. Controlled cooling can be provided. In embodiments, a high power image on the powder layer can be superimposed with a single auxiliary laser. 9A to 9F show a plan view of an embodiment of a composite image of a main image and an auxiliary image. The directions of movement of both the main beam pattern and the auxiliary beam pattern are indicated by arrows in each figure.

FIG. 9A shows an embodiment of a linear 1-D multispot main image at an angle to the direction of movement and in a state of being completely in a circular auxiliary image.

FIG. 9B is a 1-D image of a tilted array with a fusion provided by an auxiliary laser source with a main image in which the dead space between the spots is supplemented by the tilted angle of the spots. The embodiment with a single auxiliary image for preheating the powder is shown before. In this embodiment, the auxiliary images are adjacent to, but not overlapped with, the main beam pattern.

FIG. 9C shows an embodiment of a single linear array main image that overlaps with a rectangular auxiliary laser image and provides both preheating and post-fusion energy to control temperature through the build sequence. There is.

FIG. 9D overlaps with a single oval auxiliary laser spot, providing the energy required for a given scan rate to bring the powder temperature to a temperature just below the melting temperature, and after welding. It illustrates an embodiment of a spaced 2-D array pattern that provides a means for annealing a material.

FIG. 9E shows an embodiment of a 2-D main image from a dense fiber array, with a single preheated beam image from an auxiliary laser source adjacent to and in front of the main image.

FIG. 9F shows an embodiment of a 2-D main image from a dense array of adjacent square fibers. In one embodiment, the squares overlap to minimize machining gaps. This dense array pattern overlaps with an auxiliary laser source that has the strength to preheat the powder, which provides additional energy during the melting and joining process and finally after the melting and fusion steps. Provides some temperature control.

These auxiliary laser sources for the auxiliary image patterns of embodiments 9A-9F and the auxiliary laser patterns and images of other embodiments are, for example, the scan speed of the printer head, the output of the main laser beam, and heated. Depending on the size of the area, about 2 watts, about 3 watts, about 10 watts, about 20 watts, about 50 watts, about 100 watts, about 150 watts, about 50 watts to about 2 kW, about 10 watts to about 200, about It can range from 50 watts to about 500, from about 250 watts to about 1 kW, and several watts.

By combining the main laser light source of the fiber bundle with the auxiliary light source of the fiber bundle, it becomes feasible to change the temperature cycle of preheating and cooling during the shaping of the object. Thus, the cycle of the preheating and cooling process can be varied and, for example, adapted to the state in which the modeled item was modeled. Information about the characteristics of the shaped item, such as temperature, roughness, density, spectrum of illuminated or reflected light, thus changes and adjusts the characteristics, such as the on-time and output of the auxiliary fiber laser beam. Used to adjust the auxiliary image "on the fly" to the main image, the modeling of the item, or both. 10A-10F show various configurations and possible timing effects when overlaying an addressable laser image pattern with an addressable auxiliary preheating pattern. A further advantage of laser preheating is that it eliminates the need to heat the entire layer or the chamber, which requires more energy.

Temperature control system

Prior to the present invention, the conventional laminated modeling system operated in an open loop format in which print quality could not be accurately controlled. This has been a serious drawback of such conventional systems, but embodiments of the present invention address and improve it. In one embodiment of the invention, the feedback loop is used to accurately control the temperature of each of the 1-D or 2-D patterns, as well as the auxiliary laser pattern and the powder layer to which these patterns are sent. This feedback loop offers many advantages, for example, that the part to be modeled will have smaller porosity, less defects, and better surface roughness than what can be achieved with an open loop system. .. Since the gantry system moves at a relatively low speed compared to systems based on galvanometers, the temperature of the powder layer is measured at all points in the print pattern and is based on the temperature profile of the item as it is being modeled. It is feasible to change the output settings of the laser addressing the area of the print pattern in real time during the print process, for example "on the fly" to adjust the print process. In one embodiment, the temperature profile of the layer is monitored and controlled on the laser spot for each laser spot, and the output, timing, or both of the laser spots are adjusted to control the shaping process of the item. FIG. 11 illustrates how the image 1101 of the fiber bundle is reimaged 1103 on the camera sensor array 1102. The software that reads the sensor array recognizes the heated areas and provides the average temperature for each area. If the laser sources are all at the same power, the central pixel will show a much higher temperature than the outer pixels, and the power of the inner light source can be reduced until a uniform temperature profile is achieved. As a result, the powder continues to be melted and fused within the optimum temperature range. This applies not only to 2-D fiber bundle images, but also to 1-D fiber bundle images. When the temperature in that region is measured, as shown in FIG. 12, a series of command signals 1204-1210 is calculated to increase the output to each region until a uniform or predetermined optimum temperature profile is achieved. Or reduce. Thus, the image 1201 of the array or fiber bundle on the powder layer is imaged on a device for receiving and analyzing the image, for example a sensor or camera such as a FLIR camera. It provides a matrix 1202 of temperature profiles on a pixel-by-pixel basis. Processors, such as computers and microprocessors, interpolate and transform the temperature profile from matrix 1202 against the modeling program and send the control signal 1204-1210 to the laser associated with the image generated by the individual fiber or laser. Adjust the laser output to meet the modeling plan by sending. In this way, spot-by-spot on-the-fly laser beam and sculpting profile adjustments are provided. Also, by providing a feedback signal to the laser light source in real time, it is possible to increase the output to the region if the powder is not properly melted, increasing the likelihood that it will be properly melted. This can occur in regions where there is a large variation in the diameter of the powder, as larger diameter powders require more energy to melt than smaller diameter powders. It is also important to prevent the small diameter powder from vaporizing, so real-time temperature feedback to the laser source is sufficient to melt the large powder particles but to vaporize the small powder particles. Can be used to regulate within an inadequate average region temperature.

Examples of systems, processes, configurations, and methods of embodiments of the systems and methods of the present application are given in Table 1.

Also, in general, embodiments of the present invention relate to laser beam coupling, systems for such coupling, and processes utilizing coupled beams. In particular, the present invention relates to an array, an assembly, and an apparatus for coupling a laser beam from several laser beam sources to one or more coupled laser beams. These coupled laser beams preferably maintain, enhance, and both the various aspects and properties of the laser beam from the individual light sources.

A wide range of applicability is found in the array assembly and the embodiments of the coupled laser beam that provides them. The embodiment of the array assembly is compact and durable. Embodiments of the array assembly include, to name a few examples, laminated modeling including welding, 3-D printing; laminated modeling-milling systems such as addition and removal manufacturing; astronomy; meteorology; images; video including entertainment. And may be applicable to medicines including dentistry.

Although the present specification focuses on blue laser diode arrays, this embodiment merely describes the types of array assemblies, systems, processes, and coupled laser beams envisioned in the present invention. .. Accordingly, embodiments of the present invention are arrays for coupling laser beams from various laser beam sources, such as solid-state lasers, fiber lasers, semiconductor lasers, other types of lasers, and combinations and variants thereof. Includes assembly. Embodiments of the invention include laser beams across all wavelengths, such as wavelengths from about 380 nm to 800 nm (eg, visible light), from about 400 nm to about 880 nm, from about 100 nm to about 400 nm, from 700 nm to 1 mm, and various of these. Includes the combination of specific wavelength combinations within a range or the coupling of a laser beam with a modified form of wavelength. The embodiments of the array are also found to have applications in microwave coherent radiation (eg, wavelengths greater than about 1 mm). Embodiments of the array can combine beams from one, two, three, tens, or hundreds of laser sources. These laser beams can have from a few milliwatts to a few watts, a few kilowatts.

Embodiments of the invention preferably include an array of blue laser diodes combined in a structure to produce a bright laser light source. This high-intensity laser light source can be used to process materials directly, i.e. for marking, cutting, welding, brazing, heat treatment and annealing. The material to be processed, eg, the starting material or the target material, includes any material or part or composition and, to name a few examples, for example, such as, but not limited to, TFT (thin film semiconductor). Semiconductor components, starting materials for 3-D printing, metals including gold, silver, platinum, aluminum, and copper, plastics, cell tissues, and semiconductor wafers. Direct processes include, for example, gold ablation from electronic components, projection displays, and laser light shows, to name a few.

The high-intensity laser light source embodiment can be used to pump a Raman laser or an anti-Stokes laser. The Raman medium can be an optical fiber or a crystal such as diamond, KGW (potassium gadolinium tungstate, KGd (WO ₄ ) ₂ ), YVO ₄ , and Ba (NO ₃ ) ₂ . In one embodiment, the high intensity laser light source is a blue laser diode light source, which is a semiconductor operating at a wavelength in the range of 400 nm to 500 nm. The Raman medium is a luminance transducer and can increase the luminance of a blue laser diode light source. Brightness enhancement is a single mode diffraction-limited light source, ie, less than 1 mm-mrad, less than 0.7 mm-mrad, less than 0.5 mm-mrad, less than 0.2 mm-mrad, and 0.13 mm, depending on the wavelength. It leads to producing a beam with an M ² of about 1 to 1.5 with a beam parameter product of less than -mrad.

In one embodiment, the "n" or "N" (eg, 2, 3, 4, etc., tens, hundreds, or more) laser diode light sources are a bundle of optical fibers that allow addressable light sources. Addressable light sources can be configured with, to name a few examples of laser operation and methods, marking, melting, welding, melting, annealing, heat treatment, cutting of materials, and combinations and variants thereof. Can be used for.

An embodiment of a laser system comprising an addressable laser delivery configuration. The system has an addressable laser diode system. The system provides independently addressable laser beams to multiple fibers, with more or fewer fibers and laser beams planned. The fibers are bonded to a fiber bundle housed in a protective tube or cover. The fibers in the fiber bundle are fused to form a printer head containing an optical assembly that focuses the laser beam and directs it along the beam path toward the target material. The printer head and powder hopper move together as the printer head moves in the positive direction. Additional material is placed on top of the fused material as it passes through the printer head or hopper, respectively. Since the printer head is bidirectional and fuses the material in both directions as the printer head moves, the powder hopper operates behind the printer head to bring the fused laminated material onto the next path of the laser printer head. offer.

By an "addressable array", one of its output; duration of launch; sequence of launch; position of launch; output of beam; shape of beam spot and focal length, eg, transmission depth in the z-z direction. One or more can be independently varied, controlled, and pre-determined, or each laser beam of each fiber can be produced from a high precision final product of the target material (eg, molding material) with the exact pre-position. Provide a defined delivery pattern. An addressable array embodiment also has the ability of the individual beams and laser stops produced by those beams to perform a variety of predetermined and accurate laser movements such as annealing, melting, and welding. Have.

The following examples are provided to illustrate various embodiments of the laser array, system, device, and method of the present invention. These examples are for illustration purposes only and should not be seen as a limitation of the scope of the invention, nor are they limiting.

Example 1

An array of blue laser diodes that create a single spot in the distant field that is spatially coupled and coupled within a solarization-resistant optical fiber for delivery to the workpiece.

Example 2

The array of blue laser diodes according to Example 1, which is a polarized beam coupled to increase the effective brightness of the laser beam.

Example 3

An array of blue laser diodes having a space between each collimated beam in the fast axis direction of the laser diode and coupled to a periodic plate, the periodic plate reflecting the first laser diode. And an array of blue laser diodes configured to pass a second laser diode to fill the space between the laser diodes in the fast axis direction of the first array.

Example 4

A patterned mirror on a glass substrate used to achieve filling the space of Example 3.

Example 5

A patterned mirror on one side of a glass substrate to achieve filling the space of Example 3, where each laser is used to fill the empty space between the individual laser diodes. It is thick enough to move the vertical position of the diode.

Example 6

A stepped heat sink, the patterned mirror described in Example 4, which realizes filling the space of Example 3.

Example 7

The array of blue laser diodes according to Example 1, wherein each of the individual lasers is locked to a different wavelength by an external cavity, substantially increasing the brightness of the array to the equivalent brightness of a single laser diode light source.

Example 8

A separate array of laser diodes is locked to a single wavelength using an external cavity based on the grating, and each of the laser diode arrays is coupled to a single beam using a narrowly spaced optical filter or grating. The blue laser diode array according to Example 1.

Example 9

Used to pump a raman converter such as an optical fiber with a pure fused quartz silica core to create a brighter light source and a fluorinated outer core to contain the blue pump light. , An array of blue laser diodes according to Example 1.

Example 10

An optical fiber-like Raman transform having a central core to create a brighter light source, which is doped with GeO ₂ and has an outer core, and an outer core that is larger than the central core and contains blue pump light. The array of blue laser diodes according to Example 1 used to pump a vessel.

Example 11

To pump a Raman transducer such as an optical fiber with a _P2O5 doped core to create a brighter light source, an outer core larger _than the central core to contain the blue pump light, and a fiber optic-like core. The array of blue laser diodes according to Example 1 used in.

Example 12

Used to pump a raman converter, such as an optical fiber, with a refractive index distributed core to create a brighter light source and an outer core larger than the central core to contain the blue pump light. An array of blue laser diodes according to Example 1.

Example 13

An array of blue laser diodes according to Example 1, which is used to pump a Raman transducer fiber that is a refractive index distributed GeO ₂ doped core and an outer step core.

Example 14

The array of blue laser diodes according to Example ₁ used to pump a Raman transducer fiber, which is a refractive index distributed _P2O5 doped core and an outer step core.

Example 15

The array of blue laser diodes according to Example 1 used to pump a Raman transducer fiber, which is a refractive index distributed GeO ₂ doped core.

Example 16

The array of blue laser diodes according to Example ₁ used to pump a Raman transducer fiber, which is a refractive index distributed _P2O5 doped core and an outer step core.

Example 17

Other embodiments and modifications of the embodiment of Example 1 can be considered. An array of blue laser diodes according to Example 1, which is used to pump a diamond-like Raman transducer to create a brighter laser light source. FIG. 13 shows the image 1301 from the diamond chip and the spectrum 1302 of the blue Raman-converted laser beam, and also shows the wavelength shift from 450 nm to 478 nm. An array of blue laser diodes according to Example 1, which is used to pump a Raman transducer such as a KGW to produce a higher brightness laser light source. An array of blue laser diodes according to Example 1, which is used to pump a Raman transducer such as the YVO ₄ to produce a higher brightness laser light source. An array of blue laser diodes according to Example 1, which is used to pump a Raman transducer such as Ba (NO ₃ ) ₂ to produce a higher brightness laser light source. An array of blue laser diodes according to Example 1, which is used to pump a Raman converter such as a bottled gas to produce a higher brightness laser light source. An array of blue laser diodes according to Example 1, which is used to pump a crystal doped with a rare earth element to create a brighter laser light source. An array of blue laser diodes according to Example 1, which is used to pump a rare earth element-doped fiber to create a brighter laser light source. An array of blue laser diodes according to Example 1, which is used to pump the outer core of a luminance converter to produce a greater proportion of luminance increase.

Example 18

An array of Raman-transformed lasers that operate at separate wavelengths and are coupled to create a higher output light source while preserving the spatial brightness of the original light source.

Example 19

A secondary Raman in a high-brightness central core using a dual core and a filter, a fiber Bragg diffraction grating, a difference in V number for the primary and secondary Raman signals, or a difference in microbend loss. Raman fiber with means for suppressing the signal.

Example 20

N laser diodes, where N ≧ 1, independently switched on and off, imaged on a layer of powder to melt the powder and fuse it into a single component, N Laser diode.

Example 21

In the N laser diode array (N ≧ 1) of Example 1 in which the output is fiber-coupled, each fiber is arranged in a linear or non-linear form, imaged or focused on the powder, and the powder. N laser diode arrays that create an addressable array of high power laser beams that melt or fuse layer by layer into a single shape.

Example 22

One or more laser diode arrays coupled by Raman transducers, the outputs of which are fiber coupled, each fiber arranged in a linear or non-linear form, melting the powder or layer by layer into a single shape. One or more laser diode arrays that produce an addressable array of N (N ≧ 1) high power laser beams to be fused.

Example 23

N (N ≧ 1) blue laser light sources are placed behind the laser light source and placed behind the laser light source to supply a new powder layer after the fused layer while melting and fusing the powder layer. An xy mobile system that can be moved with the system.

Example 24

A z-movement system capable of increasing / decreasing the height of the part / powder layer of Example 20 after a new layer of powder has been placed.

Example 25

A z-movement system capable of increasing / decreasing the height of the part / powder layer of Example 20 after the powder layers have been fused with a laser light source.

Example 26

A bidirectional powder placement feature for Example 20, where the powder is placed directly behind the laser spot when moving in the positive x or negative x direction.

Example 27

A bidirectional powder placement feature for Example 20, where the powder is placed directly behind the laser spot when moving in the positive y direction or the negative y direction.

Example 28

A powder supply system coaxial with N (N ≧ 1) laser beams.

Example 29

A powder supply system in which powder is sent by gravity.

Example 30

A powder supply system in which the powder is accompanied by an inert gas stream.

Example 31

A powder supply system that traverses N (N ≧ 1) laser beams and places the powder in gravity directly in front of the laser beams.

Example 32

A powder supply system that traverses N (N ≧ 1) laser beams and is accompanied by an inert gas stream that intersects the laser beams.

Example 33

For example, a second harmonic generation system that uses the output of a Raman converter at 460 nm to generate light at half the wavelength of a light source laser, i.e. 230 nm, and comprises an external resonance doubling crystal such as KTP. A second harmonic generation system that prevents light of that short wavelength from propagating through optical fibers.

Example 34

For example, at 460 nm, the output of a Raman transducer is used to generate light with a wavelength of 115 nm in an external resonant doubled crystal, but the short wavelength light cannot propagate through the optical fiber, the third harmonic. Wave generation system.

Example 35

For example, at 460 nm, the output of a Raman transducer is used to generate light with a wavelength of 57.5 nm in an external resonant doubled crystal, but the short wavelength light cannot propagate through the optical fiber. Four harmonic generation system.

Example 36

Using a rare earth element-doped brightness converter such as turium that emits a laser at 473 nm when pumped by an array of 450 nm blue laser diodes, it externally emits light at half the wavelength of the light source laser, ie 236.5 nm. A second harmonic generation system that uses a resonant doubled crystal to generate, but prevents light of that short wavelength from propagating through an optical fiber.

Example 37

Using a rare earth element-doped brightness converter such as thulium that emits a laser at 473 nm when pumped by an array of 450 nm blue laser diodes, using an external resonant doubled crystal to emit 118.25 nm light. A third harmonic generation system that generates, but prevents that short wavelength light from propagating through an optical fiber.

Example 38

Using a rare earth element-doped brightness converter such as thulium that emits a laser at 473 nm when pumped by an array of 450 nm blue laser diodes, 59.1 nm light using an external resonant doubled crystal. A third harmonic generation system that generates, but prevents that short wavelength light from propagating through an optical fiber.

Example 39

Fibers and crystals doped with all other rare earth elements pumped by a high power 450 nm light source to produce visible or near-visible power can be used in Examples 34-38.

Example 40

High power visible light emission to a non-circular outer core or clad to pump the inner core of a core fiber doped with Raman or rare earth elements.

Example 41

Use of polarization-retaining fiber to improve the gain of Raman fiber by matching the polarization of the pump to the polarization of the Raman transmitter.

Example 42

An array of blue laser diodes according to Example 1, which is used to pump a Raman transducer such as an optical fiber configured to produce a higher brightness light source of a particular polarization.

Example 43

The blue laser diode according to Example 1 used to pump a Raman converter, such as an optical fiber, configured to create a brighter light source of a particular polarization and to maintain the polarization state of the pump light source. Array of.

Example 44

Used to pump a Raman transducer, such as an optical fiber, configured to produce a higher brightness light source for a particular polarization with a non-circular outer core configured to improve Raman conversion efficiency, eg The array of blue laser diodes according to 1.

Example 45

The embodiments of Examples 1-44 may also include one or more of the following parts or assemblies: a device for flattening the powder at the end of each path before the laser scans over the powder layer; larger. A device that scales the power of a laser by coupling multiple low power laser modules through a fiber coupler to produce a beam of power; multiple low powers to produce a higher power beam. A device for coupling laser modules through free space to increase the output of a blue laser module; a device for coupling multiple laser modules on a single base plate with an embedded cooler.

It should be noted that it is not necessary to provide or work on the theory underlying the novel and innovative performance, other strengths, and properties that are the subject of or related to embodiments of the present invention. Nonetheless, various theories are provided herein to further advance technologies in this important area, especially in the areas of laser, laser machining, and laser applications. Those theories presented herein do not limit, limit or narrow the scope of protection given to the claimed invention, unless explicitly stated. These theories may not be required or implemented in order to utilize the present invention. The present invention leads to new and previously unknown theories to explain the operation, function, and features of embodiments of the methods, articles, materials, devices, and systems of the invention, which will be developed later. It should be understood that such a theory does not limit the scope of protection given to the present invention.

It should be understood that the use of the titles herein is for clarity purposes and is not limited in any way. Therefore, the processes and disclosures described below the title should be read in the overall context of this specification, including various examples. The use of the titles herein should not limit the scope of protection given to the invention.

Various embodiments of systems, lasers, diodes, arrays, modules, assemblies, activities and operations described herein can be used in the fields described above and in various other fields. In particular, embodiments of the present invention can be used with the methods, devices, and systems of Japanese Patent Application Laid-Open Nos. WO2014 / 179345, 2016/0067780, 2016/0067827, 2016/0322777, 2017/0343729, 2017/0341180, and 2017/0341144. And the entire disclosure of each is included herein by reference. In addition, these embodiments include, for example, existing lasers, laminated modeling systems, operations and activities, and other existing equipment, and future lasers, laminated modeling systems, operations and activities, and in part. Can be used with such items to be improved based on the technology of the specification. Also, the various embodiments described herein can be used in various combinations that differ from each other. Thus, for example, the configurations provided in the various embodiments herein can be used interchangeably. For example, the components of the embodiment having A, A'and B and the components of the embodiment having A ", C and D are in various combinations, eg, A, C, D, and A, as taught herein. , A "C and D, etc. Thus, the scope of protection given to the present invention should not be limited to the particular embodiments, configurations, or arrangements described in the particular embodiments, examples, or embodiments of the drawings.

The present invention can be embodied in forms other than those specifically disclosed herein, without departing from its spirit or essential characteristics. The embodiments described should be considered exemplary and not limiting in all respects.

Claims (85)

A light source is provided to provide a multi-spot 1-D image, a multi-spot 2-D image, or both on a powder layer, with sufficient power density for the image to fuse and shape parts from the powder. Has a laminated modeling system. The light source of claim 1 comprises an array of fibers coupled with light from an array of fiber Raman lasers operating in the wavelength region of 300 nm to 500 nm. The light source of claim 1 comprises an array of laser diodes operating in the wavelength region of about 400 nm to about 500 nm. The light source of claim 1 comprises an array of optical fibers coupled to a laser diode operating in the wavelength range from about 400 nm to about 500 nm. The light source according to claim 1, 2, 3, 4, or 5, comprising an array of optical fibers having a diameter selected from the group consisting of 10 μm to 50 μm, 50 μm to 100 μm, and 100 μm to 500 μm. 1. Claim 1 comprising a single bundle of individual optical fibers coupled to individual light sources reimaged with optics up to 1: 0.5, 1: 1, 1: 2, and 1:10. 2, 3, 4, or 5. The light source of claim 1 is a bundle of fibers attached to a single QBH connector. The light source of claim 1 is a separate fiber attached separately. It is equipped with a high-resolution thermal detection camera for directly monitoring the temperature of each spot during operation and providing a feedback signal to the microprocessor, which controls the output to each spot to control each spot. The system according to claim 1 or 6, which controls the modeling quality of the component above. It comprises an array of pyrometers for directly monitoring the temperature of each spot during operation and providing a feedback signal to the microprocessor, which controls the output to each spot and on each spot. The system according to claim 1 or 6, which controls the modeling quality of the component. 1-10. A printer head comprising an array of light sources mounted on an xy gantry system for traversing the 1-D or 2-D image over the surface of the powder layer. The system according to any one of the above. The laminated modeling system according to claim 1, wherein a gravity feed powder supply system operating in both directions is used. The laminated modeling system according to claim 1, comprising a rotating wheel that moves in the direction opposite to the direction of movement of the hopper and squeezes and compresses the powder to reduce voids in the powder layer. The control signal according to claim 85 includes a signal proportional to the temperature of the powder layer. The control signal according to claim 85 includes a signal proportional to the temperature of the molten metal pool formed at each point of the 1-D or 2-D image on the powder layer. The laminated modeling system of claim 1 uses a blue laser light source to fuse the copper powder. The laminated modeling system of claim 1 uses a blue laser light source to fuse the gold powder. The laminated modeling system of claim 1 uses a blue laser light source to optimally fuse the aluminum powder. The laminated modeling system of claim 1 uses a blue laser light source to fuse all metals and alloys. The printer head for the laminated modeling system according to claim 11 integrates an optical system with a thermal detection camera system, reimages the printer head, and exhibits the image of the fiber array or diode array in the region. The temperature of the powder is controlled. The optical system of the printer head of the laminated modeling system according to claim 11 comprises a collimeter which is a set of a plano-convex lens, a plano-convex aspherical lens, and a double or triple lens, and the condensing optical element is a plano-convex lens. It is composed of a plano-convex aspherical lens, and the light source is 1f away from the collimating lens and 1f away from the condenser lens. The optical system in the printer head according to claim 11 is a re-imaging optical element including the light source at least 2f away from the lens and the image 2f away from the lens in the opposite direction. The laminated modeling system according to claim 1, wherein a piston is used to supply the powder to the printer layer for redelivery. A laminated modeling system based on an array of light sources and an auxiliary light source that is a 1-D or 2-D image on a powder layer with sufficient output density to fuse and shape the components, using a camera system. , Monitor each pixel of the image and feed back control signals to each laser in real time to control the melting and fusion of the powder and optimize the resulting component surface roughness, void ratio, and stress. A laminated modeling system that controls the temperature of the modeling area as described above. The light source according to claim 24 is an array of Raman lasers operating in the wavelength region of 300 nm to 500 nm. The light source according to claim 24 is an array of laser diodes operating in the wavelength region of 400 nm to 500 nm. 24. The light source of claim 24, which is an array of optical fibers coupled to a laser diode operating in the wavelength range of 400 nm to 500 nm. The light source of claim 24 is delivered by an array of optical fibers ranging in diameter from 10 μm to 50 μm, 50 μm to 100 μm, or 100 μm to 500 μm. The light source of claim 24 is a single piece of individual optical fiber coupled to a separate light source reimaged with optics up to 1: 0.5, 1: 1, 1: 2, and 1:10. It is a bundle of. The light source of claim 24 is a bundle of fibers attached to a single QBH connector. The light source of claim 24 is a separate fiber attached separately. The light source according to claim 24 is a Raman laser that operates in a wavelength region of 300 nm to 500 nm. The auxiliary light source according to claim 24 is a laser diode system operating in a wavelength region of 400 nm to 500 nm. The auxiliary light source according to claim 24 is formed on the same area as the area where the 1-D or 2-D pattern is formed. The temperature of the powder irradiated by the auxiliary light source of claim 24 is measured by a heat detection camera, and the signal from the camera is used to control the average temperature of the irradiated area. The temperature of the powder irradiated by the auxiliary light source of claim 24 is measured by a pyrometer, and the signal from the pyrometer is used to control the average temperature of the irradiated area. The camera of claim 24 is a high resolution thermal detection camera for directly monitoring the temperature of each spot during operation and providing a feedback signal to the microprocessor, wherein the microprocessor outputs the output to each spot. To control the modeling quality of the component on each spot. The camera of claim 24 is an array of pyrometers for directly monitoring the temperature of each spot during operation and providing a feedback signal to the microprocessor, which controls the output to each spot. Controls the modeling quality of the component on the spot. The laminated modeling system according to claim 24 is a printer head having an array of light sources mounted on an xy gantry system for traversing the 1-D or 2-D image over the surface of the powder layer. Is based on. 24. The laminated modeling system according to claim 24, which uses a gravity feed powder feeding system that operates in both directions. 24. The laminated modeling system of claim 24, wherein a piston is used to supply the powder to the printer layer for resupply. 24. The laminated modeling system of claim 24, comprising a rotating wheel that moves in the direction opposite to the direction of movement of the hopper and squeezes and compresses the powder to reduce voids in the powder layer. The control signal according to claim 24 can be a signal proportional to the temperature of the powder layer. The control signal according to claim 24 includes a signal proportional to the temperature of the molten metal pool formed at each point of the 1-D or 2-D image on the powder layer. The laminated modeling system of claim 24 uses a blue laser light source to fuse the copper powder. The laminated modeling system of claim 24 uses a blue laser light source to fuse the gold powder. The laminated modeling system of claim 24 uses a blue laser light source to optimally fuse the aluminum powder. The laminated modeling system of claim 24 uses a blue laser light source to optimally fuse all metals and alloys. The printer head for the laminated modeling system of claim 1 integrates the optical system with a thermal detection camera system, re-images and said in the region exposed to the image of the fiber array or diode array. The temperature of the powder is controlled. The optical system of the printer head of the laminated modeling system according to claim 1 comprises a collimator which is a set of a plano-convex lens, a plano-convex aspherical lens, and a double or triple lens, and the condensing optical element is a plano-convex lens. It is composed of a plano-convex aspherical lens, and the light source is 1f away from the collimating lens and 1f away from the condenser lens. The optical system in the printer head is a re-imaging optical element having the light source at least 2f away from the lens and the image 2f away from the lens in the opposite direction. The laminated modeling system of claims 1 and 24 incorporates an optical coherence tomography (OCT) system into the real-time monitoring of the welding process. An array of light sources and an array of auxiliary light sources (nx) for controlling the temperature of the modeling area, which is a 1-D or 2-D image on a powder layer with sufficient output density to fuse and model the components. It is a laminated modeling system based on m> 1), and a camera system is used to monitor each pixel of the image and feed back a control signal to each laser in real time to melt and fuse the powder. A laminated modeling system that controls and optimizes the surface roughness, void ratio, and stress of the resulting component. The light source of claim 53 is an array of fibers coupled with light from an array of fiber Raman lasers operating in the wavelength region of 300 nm to 500 nm. The light source according to claim 53 is an array of laser diodes operating in the wavelength region of 400 nm to 500 nm. 53. The light source according to claim 53, which is an array of optical fibers coupled to a laser diode operating in the wavelength region of 400 nm to 500 nm. The light source of claim 53 is delivered by an array of optical fibers ranging in diameter from 10 μm to 50 μm, 50 μm to 100 μm, or 100 μm to 500 μm. The light source of claim 53 is a single piece of individual optical fiber coupled to a separate light source reimaged with optics up to 1: 0.5, 1: 1, 1: 2, and 1:10. It is a bundle of. The light source of claim 53 is a bundle of fibers attached to a single QBH connector. The light source of claim 53 is a separate fiber attached separately. The light source according to claim 53 is a fiber Raman laser operating in a wavelength region of 300 nm to 500 nm. The auxiliary light source according to claim 53 is a laser diode system operating in a wavelength region of 400 nm to 500 nm. The auxiliary light source according to claim 53 is formed on the same area as the area where the 1-D or 2-D pattern is formed. The temperature of the powder irradiated by the array of auxiliary light sources of claim 53 is measured by a thermal detection camera and the signal from the camera is used to control the average temperature of the irradiated area. .. The temperature of the powder irradiated by the auxiliary light source of claim 53 is measured by a pyrometer, and the signal from the pyrometer is used to control the average temperature of the irradiated area. The camera of claim 53 is a high resolution thermal detection camera for directly monitoring the temperature of each spot during operation and providing a feedback signal to the microprocessor, wherein the microprocessor outputs the output to each spot. To control the modeling quality of the component on each spot. The camera of claim 53 is an array of pyrometers for directly monitoring the temperature of each spot during operation and providing a feedback signal to the microprocessor, controlling the output to each spot on each spot. Controls the modeling quality of the component. The laminated modeling system of claim 53 has a printer head having an array of light sources mounted on an xy gantry system for traversing the 1-D or 2-D image over the surface of the powder layer. Is based on. The laminated modeling system according to claim 53, which uses a gravity feed powder feeding system that operates in both directions. 53. The laminated modeling system of claim 53, wherein a piston is used to supply the powder to the printer layer for resupply. 53. The laminated modeling system according to claim 53, comprising a rotating wheel that moves in the direction opposite to the direction of movement of the hopper and squeezes and compresses the powder to reduce voids in the powder layer. The control signal according to claim 53 can be a signal proportional to the temperature of the powder layer. The control signal according to claim 53 can be a signal proportional to the temperature of the molten metal pool formed at each point of the 1-D or 2-D image on the powder layer. The printer head for the laminated modeling system according to claim 1 incorporates an optical system into a thermal detection camera system, reimages the temperature of the powder in a region exposed to the fiber array or diode array image. To control. The optical system in the printer head of the laminated modeling system according to claim 1 comprises a collimator which is a set of a plano-convex lens, a plano-convex aspherical lens, and a double or triple lens, and the condensing optical element is a plano-convex lens. It is composed of a plano-convex aspherical lens, and the light source is 1f away from the collimating lens and 1f away from the condenser lens. The optical system in the printer head is a re-imaging optical element having the light source at least 2f away from the lens and the image 2f away from the lens in the opposite direction. The laminated modeling system of claim 53 uses a blue laser light source to fuse the copper powder. The laminated modeling system of claim 53 uses a blue laser light source to fuse the gold powder. The laminated modeling system of claim 53 uses a blue laser light source to optimally fuse the aluminum powder. The laminated modeling system of claim 53 uses a blue laser light source to optimally fuse all metals and alloys. The printer heads of claims 1, 24, and 53 are mounted on a single or multiple gantry together with similar printer heads to print images in parallel. The printer heads of claims 1, 24, and 53 are mounted on a single or multiple gantry together with similar printer heads to print the image that is part of a component. The printer heads of claims 1, 24, and 53 are mounted on a single or multiple gantry with similar printer heads, and the optical system combines the images from the plurality of light sources together to further. Used to generate large continuous images. The printer heads of claims 1, 24, and 53 are mounted on a single or multiple gantry together with similar printer heads, and print images in a checkerboard shape combined by step-and-repeat of a grid pattern. do. A camera that monitors each pixel of the image and feeds back control signals to each laser in real time to control the melting and fusion of the powder and optimize the resulting surface roughness, void ratio, and stress of the component. The system according to claim 1, further comprising a system.

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