JP2024020355A - Applications, methods, and systems for laser-delivered addressable arrays - Google Patents

Abstract

A laser processing system that combines a variety of laser beam sources into a single or multiple laser beams while maintaining and enhancing desired beam qualities such as brightness and power. An addressable array laser processing system comprising at least three laser systems 501 and at least three laser diode assemblies and spatially coupling a laser beam to maintain its brightness. and means for Each laser diode assembly includes at least ten laser diodes. Each laser system couples each of the combined laser beams into a single optical fiber 502a, 502b, 502c. The control system has a program with a predetermined sequence for delivering each of the combined laser beams to a predetermined location on the target material 507. [Selection diagram] Figure 5

Description

The present application is
(i) claims the benefit of U.S. Provisional Patent Application No. 62/193,047, filed July 15, 2015, under 35 United States Code, Section 119(e)(1); , the entire disclosures of each of which are hereby incorporated by reference.

The present invention relates to array assemblies for combining laser beams, particularly in the manufacturing, fabrication, entertainment, graphics, imaging, analysis, monitoring, assembly, dental, and medical fields. The present invention relates to an array assembly capable of providing a high intensity laser beam for use in systems and applications.

Many lasers, particularly semiconductor lasers such as laser diodes, provide laser beams with highly desirable wavelengths and highly desirable beam qualities, including brightness. These lasers can have wavelengths in the visible range, wavelengths in the UV range, wavelengths in the IR range, and combinations thereof, or even higher and lower wavelengths. The technology of semiconductor lasers and other laser sources, such as fiber lasers, is rapidly evolving, and new laser sources are constantly being developed to provide existing and new laser wavelengths. Although many of these lasers have desirable beam quality, they have lower laser power than is desired or required for a particular application. Thus, their low powers have prevented these laser sources from finding more useful commercial applications.

In addition, previous efforts to combine these types of lasers have been hampered by difficulties in beam alignment and keeping the beam aligned throughout the application, to name a few other reasons. They have generally been unsatisfactory due to maintenance difficulties, loss of beam quality, special installation difficulties of the laser source, size considerations, and power management.

As used herein, unless expressly stated otherwise, the terms "blue laser beam," "blue laser," and "blue" are to be given their broadest meanings and, in general, Refers to a system for providing a laser beam, a laser beam, a laser light source, such as a laser and a diode laser, that provides, e.g. propagates, a laser beam or light having a wavelength of about 400 nm to about 500 nm.

Generally, as used herein, unless explicitly stated otherwise, the term "about" refers to the variance or range of ±10%, the experimental or instrumental error associated with obtaining the stated value, and preferably The larger of these shall be covered.

The Background of the Invention section is intended to introduce various aspects of the art that may be associated with embodiments of the present invention. Accordingly, the above discussion in this section provides a framework for a deeper understanding of the invention and is not to be construed as an admission of prior art.

U.S. Provisional Patent Application No. 62/193,047 International Publication No. 2014/179345 U.S. Patent Application No. 14/787,393

Among other things, there is a need for assemblies and systems that combine diverse laser beam sources into a single or multiple laser beams while maintaining and enhancing desired beam qualities such as brightness and power. It has existed for many years and has not yet been fulfilled. The present invention solves these needs by providing, among other things, articles of manufacture, apparatus, and processes taught and disclosed herein.

A laser system is provided for performing laser operations, the system comprising a plurality of laser diode assemblies; each laser diode assembly directing a separate blue laser beam along a laser beam path. a plurality of laser diode assemblies having a plurality of laser diodes capable of generating a target material; means for producing a combined laser beam capable of being coupled into an optical fiber for delivery to; Optically associated with a diode.

Additionally, methods and systems are provided having one or more of the following features. That is, it has at least three laser diode assemblies; each laser diode assembly has at least 30 laser diodes; the laser diode assemblies have a total power of at least about 30 watts and less than 20 mm mrad. A laser beam having a beam parameter characteristic can be propagated; the beam parameter characteristic is less than 15 mm mrad; the beam parameter characteristic is less than 10 mm mrad; generating a combined laser beam of brightness; where N is the number of laser diodes in the laser diode assembly; the spatially combining means increases the power of the combined laser beam while maintaining the brightness of the blue beam; the combined laser beam has a power at least 50 times that of the individual laser beams, and the beam parameter product of the combined laser beam is less than or equal to twice the beam parameter product of the individual laser beams; the beam parameter product of the combined laser beam is The beam parameter product of the combined laser beam is less than 1.5 times the beam parameter product of the individual laser beams; the beam parameter product of the combined laser beam is less than 1 times the beam parameter product of the individual laser beams; Increase the power of the laser beam while maintaining brightness; the combined laser beam has a power at least 100 times that of the individual laser beams, and the beam parameter product of the combined laser beam is 2 times the beam parameter product of the individual laser beams. The beam parameter product of the combined laser beam is not more than 1.5 times the beam parameter product of the individual laser beams; The beam parameter product of the combined laser beam is not more than 1 times the beam parameter product of the individual laser beams the optical fiber is solarization resistant; the spatial coupling means is selected from the group consisting of aligned plane parallel plates and wedges for correcting at least one of position errors or aiming errors of the laser diode; the spatially combining means comprises a polarizing beam combiner capable of increasing the effective brightness of the combined laser beam over the individual laser beams; the laser diode assembly comprises an individual laser diode assembly; The laser beam paths are defined with a space between each path such that the individual laser beams have a space between each beam; the means for spatially coupling the individual laser beams with a laser diode. a collimator for collimating on a fast axis of the laser beam, and a periodic mirror for combining the collimated laser beams, the periodic mirror reflecting the first laser beam from the first diode in the laser diode assembly. , transmitting a second laser beam from a second diode in the laser diode assembly, thereby filling the fast-axis space between the individual laser beams; Has a patterned mirror; The glass substrate is thick enough to shift the vertical position of the laser beam from the laser diode to fill the space between the laser diodes; Has a stepped heat sink Provided are methods and systems having one or more of the following:

Still further, a laser system for providing a high brightness, high power laser beam is provided, the system comprising a plurality of laser diode assemblies; each laser diode producing a blue laser beam having an initial brightness. a plurality of laser diode assemblies, having a plurality of laser diodes that can be coupled to the optical fiber; and spatially combining the blue laser beams to form a single spot in the far field with a final brightness; means for producing a combined laser beam capable of being coupled into a laser diode, each laser diode being locked to a different wavelength by an external cavity so as to substantially increase the brightness of the combined laser beam; Therefore, the final brightness of the combined laser beam is approximately the same as the initial brightness of the laser beam from the laser diode.

Additionally, methods and systems are provided having one or more of the following features. That is, each laser diode is locked to a single wavelength using an external cavity based on a diffraction grating, and each of the laser diode assemblies is coupled to a narrowly spaced optical filter selected from the group consisting of a diffraction grating. The Raman converter has a pure fused silica core to reveal the higher brightness light source and a fluorinated outer core to house the blue pump light. The Raman converter is an optical fiber having a GeO2-doped central core and an outer core to reveal a higher brightness light source, and an outer core larger than the central core to accommodate the blue pump light. used to pump a Raman converter such as an optical fiber with a P2O5 doped core to reveal a higher brightness light source, and a P2O5 doped core to house the blue pump light. A Raman converter is an optical fiber having an outer core that is larger than the central core; an outer core that is larger than the core; the Raman converter is a graded index GeO2 doped core and an outer step index core; the Raman converter is a graded index P2O5 doped core; The Raman converter is used to pump a Raman converter fiber that is a graded index core and a stepped index outer core; Used in; Raman converter is graded index type P2O5 doped core and outer step index type core; Raman converter is diamond to reveal higher brightness laser light source ; Raman converter is KGW to develop higher brightness laser light source; Raman converter is YVO4 to develop higher brightness laser light source; Raman converter is higher one or more of: Ba(NO3)2 to generate a laser light source of higher brightness; and the Raman converter is a high pressure gas to generate a laser light source of higher brightness. A method and system are provided.

Still further, a laser system for performing a laser operation is provided, the system comprising a plurality of laser diode assemblies; each laser diode assembly generating a blue laser beam along a laser beam path. a multi-laser diode assembly having a plurality of laser diodes capable of spatially coupling a blue laser beam and optically coupling it to a Raman converter with a single spot in the far field; and means for pumping the Raman converter to increase the brightness of the combined laser beam.

Additionally, a method is provided for providing a combined laser beam, the method comprising the steps of: operating an array of Raman conversion lasers to produce separate, different wavelength blue laser beams; and combining the laser beams. to reveal a higher power light source while maintaining the spatial brightness of the original light source.

Furthermore, a laser system is provided for performing a laser operation, the system comprising a plurality of laser diode assemblies; each laser diode assembly directing a blue laser beam along a laser beam path. a plurality of laser diode assemblies having a plurality of laser diodes capable of generating; an optical element for collimating and combining a beam along a laser beam path, the optics capable of providing a combined laser beam; and an optical fiber for receiving the combined laser beam.

Additionally, the method and system have one or more of the following features, wherein the optical fiber is in optical communication with the rare earth doped fiber, such that the combined laser beam is rare earth doped. The optical fiber can be pumped to reveal a higher brightness laser light source; and the optical fiber is in optical communication with the outer core of the brightness converter, such that the combined laser beam is Methods and systems are provided having one or more of: the outer core of a brightness converter can be pumped to exhibit a higher brightness enhancement ratio.

Still further, a Raman fiber is provided, the Raman fiber having dual cores, one of which has a high brightness central core; and for suppressing secondary Raman signals in the high brightness central core; a filter, a fiber Bragg grating, a V number difference for the first and second order Raman signals, and a microbend loss difference.

In addition, a second harmonic generation system is provided, the system comprising: a Raman converter for generating light at a first wavelength and half the wavelength of the first wavelength; an externally resonant doubling crystal configured to prevent light from propagating through the optical fiber;

Additionally, the method and system have one or more of the following features: the first wavelength is about 460 nm; the externally resonant doubling crystal is KTP; the Raman converter is a Raman converter. A method and system is provided having one or more of: a non-circular outer core configured to improve efficiency.

Additionally, a third harmonic generation system is provided, the system comprising: a Raman converter for generating light at a second wavelength at a first wavelength and lower than the first wavelength; an externally resonant doubling crystal configured to prevent light from propagating through the optical fiber;

Additionally, a fourth harmonic generation system is provided, the system transmitting 57.5 nm light to an external source configured to prevent light at the 57.5 nm wavelength from propagating through the optical fiber. It has a Raman converter, which generates it using a resonant doubling crystal.

Additionally, a second harmonic generation system is provided that emits a 473 nm laser when pumped by an array of 450 nm blue laser diodes and uses an externally resonant doubling crystal to convert the source laser. It has a rare earth doped brightness converter with thulium that produces light at half wavelength or 236.5 nm and does not allow shorter wavelength light to propagate through the optical fiber.

Additionally, a third harmonic generation system is provided which emits a 473 nm laser when pumped by an array of 450 nm blue laser diodes and a 118.25 nm laser using an externally resonant doubling crystal. of light and does not allow short wavelength light to propagate through the optical fiber.

Additionally, a fourth harmonic generation system is provided which emits a 473 nm laser when pumped by an array of 450 nm blue laser diodes and a 59.1 nm laser using an externally resonant doubling crystal. of light and does not allow short wavelength light to propagate through the optical fiber.

Additionally, a laser system for performing a laser operation is provided, the system comprising at least three laser diode assemblies; each of the at least three laser diode assemblies having at least ten lasers. diodes, each of the at least ten laser diodes being capable of generating a blue laser beam along a laser beam path having a power of at least about 2 Watts and a beam parameter product of less than 8 mm-mrad; at least three laser diode assemblies, each laser beam path being essentially parallel, thereby defining a space between the laser beams traveling along the laser beam path; all of the at least 30 laser beam paths; means for spatially combining a blue laser beam to maintain brightness, the means comprising: a collimating optical element for a first axis of the laser beam; and a collimating optical element for a second axis of the laser beam; a vertical prism array; and a telescope; whereby the means for spatially coupling and maintaining brightness directs the laser energy into the space between the laser beams; to provide a combined laser beam with a power of at least about 600 watts and a beam parameter product of less than 40 mm-mrad.

Furthermore, an addressable array laser processing system is provided. The addressable array laser processing system comprises at least three laser systems of the type presently described; each of the at least three laser systems coupling its respective combined laser beam into a single optical fiber. each of the at least three combined laser beams can be transmitted along a respective combined optical fiber; the at least three optical fibers are optically associated with a laser head; and a control system having a program having a predetermined sequence for delivering each of the combined laser beams to a predetermined location on the target material.

Additionally, methods and systems for addressable arrays are provided having one or more of the following features. That is, a predetermined sequence for delivery involves individually turning on and off the laser beam from the laser head, thereby imaging it onto the powder bed to melt and fuse the target material with the powder into the part. the fibers in the laser head are arranged in an array selected from the group consisting of linear, nonlinear, circular, rhombic, square, triangular, and hexagonal; 5x2, 4x5, at least 5xat least 5, 10x5, 5x10, and 3x4; the target material has a powder bed; an x-y motion system capable of moving a head thereby melting and merging the powder bed; powder positioned behind the laser light source to provide an additional powder layer behind the fused layer; a delivery system; a z-motion system capable of moving the laser head to increase and decrease the height of the laser head above the surface of the powder bed; a delivered laser beam; has a two-way powder placement device that can place powder directly behind the laser beam as the laser beam advances in the positive x direction or the negative x direction; has a powder feeding system that is coaxial with the multiple laser beam paths; have a gravity powder feeding system; have a powder feeding system in which the powder is entrained in a flow of inert gas; have a powder feeding system transverse to the N laser beam; with a powder feeding system in which N≧1 and the powder is placed in front of the laser beam by gravity; and with a powder feeding system transverse to the laser beam of N. an addressable array having one or more of the following: where N≧1 and the powder is entrained in a flow of inert gas intersecting the laser beam; Methods and systems are provided for.

Furthermore, a method is provided for providing a combined blue laser beam with high brightness, the method comprising: operating a plurality of Raman conversion lasers to provide a plurality of individual blue laser beams; combining the laser beams to reveal a higher power light source while maintaining the spatial brightness of the original light source, wherein individual laser beams of the plurality of laser beams have different wavelengths; ing.

Also provided is a method for laser processing a target material, the method comprising operating an addressable array laser processing system having at least three laser systems of the type of the system currently described to produce three individual laser processing systems. producing combined laser beams of into three separate optical fibers; transmitting each combined laser beam along its respective optical fiber to a laser head; and the three separate combined laser beams from the laser head. directing the target material to a predetermined location on the target material in a predetermined sequence.

3 is a graph showing laser performance of embodiments according to the present invention. 1 is a schematic diagram of a laser diode and an axial focusing lens according to the invention; FIG. 1 is a schematic diagram of an embodiment of a laser diode spot after fast-axis and slow-axis focusing according to the present invention; FIG. 1 is a perspective view of an embodiment of a laser diode assembly according to the present invention; FIG. 1 is a perspective view of an embodiment of a laser diode module according to the present invention; FIG. 2C is a partial view of the embodiment of FIG. 2C illustrating a laser beam, a laser beam path, and a space between the laser beams according to the invention; FIG. 2E is a cross-sectional view of the laser beam of FIG. 2E, the laser beam path, and the space between the laser beams; FIG. 1 is a perspective view of an embodiment of a laser beam, beam path, and optical element according to the present invention; FIG. FIG. 3 is a diagram of a combined laser diode beam after a patterned mirror according to the present invention; FIG. 3 is a diagram of a laser diode beam after a beam folder with equal splitting of the beam according to the invention; FIG. 3 is a diagram of a laser diode beam after a beam folder with a 3-2 column split according to the invention; 1 is a schematic diagram depicting an embodiment of the starting or scanning of an embodiment of a laser diode array over a target material according to the present invention; FIG. 1 is a table providing processing parameters according to the present invention; 1 is a schematic diagram of an embodiment of a laser array system and process according to the present invention. 1 is a schematic diagram of an embodiment of a laser array system and process according to the present invention. 1 is a schematic diagram of an embodiment of a laser array system and process according to the present invention. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG. 1 is a schematic diagram of an embodiment of a laser fiber bundle arrangement for use in an embodiment of a laser array system according to the present invention; FIG.

In general, the present invention relates to combining laser beams, systems for creating these combinations, and processes that utilize the combined beams. In particular, the present invention relates to arrays, assemblies, and apparatus for combining laser beams from several laser beam sources into one or more combined laser beams. These combined laser beams desirably have various aspects and properties of the laser beams from the individual light sources that are maintained, enhanced, or both maintained and enhanced.

Embodiments of the present array assemblies and the combined laser beams they provide may find wide applicability. Embodiments of the present array assembly are compact and robust. Possibilities for the array assembly include additive manufacturing including welding, 3D printing; additive manufacturing-milling systems such as additive manufacturing; astronomy; meteorology; imaging; entertainment, to name a few. It has applicability to projection; and medical applications including dentistry.

Although this specification focuses on blue laser diode arrays, this embodiment is merely illustrative of the types of array assemblies, systems, processes, and combined laser beams contemplated by the present invention. I want you to understand. Thus, embodiments of the present invention combine laser beams from a variety of laser beam sources, such as solid state lasers, fiber lasers, semiconductor lasers, and other types of lasers, as well as combinations and variations thereof. including an array assembly for. Embodiments of the present invention combine laser beams over all wavelengths, e.g., from about 380 nm to 800 nm (e.g., visible light), from about 400 nm to about 880 nm, from about 100 nm to 400 nm, from about 700 nm to 1 mm. wavelengths, and combinations and variations of specific wavelengths within these various ranges. Embodiments of the present array may also find applicability in microwave coherent radiation (eg, wavelengths greater than about 1 mm). Embodiments of the present array can combine beams from one, two, three, tens, or hundreds of laser sources. These laser beams can have power from a few milliwatts to a few watts to a few kilowatts.

Embodiments of the invention preferably consist of an array of blue laser diodes combined in a configuration to reveal a high intensity laser light source. This high intensity laser light source could be used to directly process materials, ie, stamp, cut, weld, braze, heat treat, anneal, etc. The material to be processed, e.g. the starting material or the target material, may include any material or component or composition, to name a few, but not limited to, semiconductor devices such as TFTs (Thin Film Transistors). , 3D printing starting materials, metals including gold, silver, platinum, aluminum, and copper, plastics, tissues, and semiconductor wafers. Direct processing can include, for example, ablation of gold from electronic equipment, projection displays, and laser light shows, to name a few.

Embodiments of the present high intensity laser light source can also be used to pump Raman or anti-Stokes lasers. The Raman medium may be a fiber optic or a crystal such as diamond, KGW (potassium gadolinium tungstate, KGd(W04)2), YVO4, and Ba(NO3)2. In some embodiments, the high intensity laser light source is a blue laser diode light source, which is a semiconductor device operating in the wavelength range of 400 nm to 500 nm. The Raman medium is a brightness converter and can increase the brightness of a blue laser diode light source. The brightness enhancement extends to reveal a single mode diffraction limited light source, i.e. the beam will have M2 values of approximately 1 and 1.5, and the beam parameter product will depend on the wavelength. less than 1 mm-mrad, less than 0.7 mm-mrad, less than 0.5 mm-mrad, less than 0.2 mm-mrad, and less than 0.13 mm-mrad.

In some embodiments, "n" or "N" (e.g., two, three, four, etc., tens, hundreds, or more) laser diode sources can be configured into a bundle of optical fibers. , so that it can be used to engrave, melt, weld, ablate, anneal, heat treat, cut, and bond and deform forms of materials, to name a few of the laser operations and treatment procedures. addressable light sources that can be used.

An array of blue laser diodes can also be combined with an optical assembly to create a high brightness direct diode laser system that can provide a high brightness combined laser beam. Figure 1 shows the laser performance of embodiments (beam parameter product vs. 100 shows a table 100 for laser power W (watts). Line 101 depicts the performance for certain embodiments of laser diode arrays. Line 102 depicts the performance of a dense wavelength beam combining array. Line 103 depicts the performance of the brightness conversion technique when scaled using the fiber combiner technique. Line 104 depicts the performance of the brightness conversion technique when using dense wavelength combination of the brightness converter output. This allows the combined beam to remain in a single spatial mode or nearly a single spatial mode as the power level is scaled. The dense wavelength combining step uses a diffraction grating to control the wavelength of each individual intensity-converted laser and then combines the beams into a single beam by the diffraction grating. The grating can be a ruled grating, a holographic grating, a fiber Bragg grating (FBG), or a volume Bragg grating (VBG). Additionally, although the preferred embodiment uses a diffraction grating, it is also possible to use a prism.

FIG. 2A is a schematic diagram of a laser diode 200 propagating a laser beam along a laser beam path to a fast axis collimating lens 201 (FAC). 1.1 mm, 1.1 mm, 1.1 mm, 1.1 mm, 1.1 mm, 1.1 mm, 1.5 mm, 1.1 mm, 1.5 mm, 1.1 mm, 1.1 mm, 1.5 mm, 1.1 mm, 1.5 mm, 1.5 mm, 1.5 mm, 1.5 mm, 1.5 mm, 1.5 mm, 1.5 mm, 1.5 mm, 1.5 mm, 1.5 mm, 1.5 mm, 1.5 mm, 1.5 mm, 1.5 mm, 1.1 mm, 1. 2mm, 1.5mm, 2mm, or even 4mm cylindrical aspheric lenses have been used. Collimating lens 202 is for collimating the slow axis (the axis with a smaller divergence angle, typically the x-axis) of the laser diode. A cylindrical aspheric lens with a focal length of 15 mm, 16 mm, 17 mm, 18 mm, or 21 mm captures the slow axis power and collimates the slow axis to maintain the brightness of the laser source. The focal length of the slow axis collimator provides optimized coupling of the laser beamlets to the target fiber diameter by the optical system. In a preferred embodiment of the array, both slow-axis and fast-axis collimating lenses are positioned along each laser beam path and are used to shape the individual laser beams.

FIG. 2B is a schematic diagram of a laser beam spot 203 formed by a laser beam from a laser diode passing through both a fast-axis focusing lens and a slow-axis focusing lens. This simulation takes into account the maximum divergence of the light source across the full aperture of the light source. It is understood that many different shapes of the laser beam spot can be created, such as square, rectangular, circular, elliptical, linear, and combinations and variations of these and other shapes. For example, the combined laser beam reveals a spot 203 using blue laser light, focused to a spot size of 100 μm, with a 100 mm focal length lens, and a NA of 0.18.

2C and 2D, a laser diode module 220 having a laser diode subassembly 210 (e.g., diode module, bar, plate, multi-die package) and four laser diode assemblies 210, 210a, 210b, 210c is shown. An embodiment is shown.

A detailed view of a portion of laser beams 250a, 251a, 252a along their respective laser beam paths 250, 251, 252 is shown in FIG. 2E. FIG. 2F is a cross-sectional view of the laser beam of FIG. 2E, showing the horizontal direction 260 and vertical direction 261 (based on the orientation of the figure) of open space. Beam combining optics bring these beams together to eliminate open space, eg 260, 261, at the final spot 203 (FIG. 2B).

Laser diode module 220 is capable of generating a combined laser beam, preferably a combined blue laser beam having the performance of curve 101 in FIG. Laser diode assembly 210 has a base plate 211 of a thermally conductive material, e.g. copper, having power leads (eg wires), e.g. 212, extending therein to provide electrical power to the diode e.g. 213. are doing. In this multi-die package embodiment, twenty laser diodes, e.g. 213, are arranged in a 5x4 configuration behind the cover plate. Other configurations are also envisioned to provide nxn diodes in the assembly, such as 4x4, 4x6, 5x6, 10x20, 30x5, and configurations currently under development, and combinations and variations thereof. Each diode has a plane parallel plate for translating the position of the beam in the slow axis e.g. 214 when using a single slow axis collimating (SAC) lens across multiple rows e.g. 216. You can. If a separate slow-axis lens is used for each laser diode, as the preferred embodiment does, then a plane-parallel plate is not necessary. As a result of the assembly process, the plane parallel plate corrects the position of the laser beam path in the slow axis as it propagates from each of the individual laser diodes. A plane parallel plate is not required if a separate FAC/SAC lens pair is used for each laser diode. The SAC position compensates for any assembly errors within the package. The results of both of these approaches improve alignment of the beamlets when using individual lens pairs (FAC/SAC) or when using individual FAC/plane parallel plates followed by a shared SAC lens. 251a, 252a, 250a and beam paths such as 251, 252, 250.

The combined beam from each of the laser diode subassemblies, e.g. 210, 210a, 210b, 210c, redirects the beams from the four laser diode subassemblies into a single beam as shown in FIG. 2G. It propagates to a patterned mirror used for coupling, e.g. 225. Four rows of collimated laser diodes are interlaced with four rows of three other packages to reveal a composite beam. FIG. 2H shows the position of the beam, eg 230, from laser subassembly 210. Aperture stop 235 trims any unwanted scattered light from the combined beamlets and reduces the thermal load on the fiber input face. A polarizing beam folding assembly 227 folds the beam in half on the slow axis to double the brightness of the combined laser diode beam (FIG. 2I). The beams may alternatively be folded to yield the pattern shown in FIG. 21 by splitting a central central emitter, in which case beam 231 is polarized in the slow axis direction. The beam 232 is a split beamlet that does not overlap any other emitter. The beam folding section is even more efficient when the beam is split between a second and a third beamlet (Fig. 2J), where two of the columns of beams, e.g. 233, are superimposed, while the The third column, for example 234, simply passes through. Telescope assembly 228 expands the slow axis or compresses the fast axis of the combined beam to allow the use of smaller lenses. The telescope 228 shown in this example (FIG. 2G) expands the beam by a factor of 2.6, increasing its size from 11 mm to 28.6 mm, and still retaining the same 2.6 times magnification. This reduces the slow axis divergence. If the telescope assembly compresses the fast axis, then it is a double telescope that lowers the fast axis from a height of 22mm (total composite beam) to a height of 11mm giving a composite beam of 11mm x 11mm. become. This is the preferred embodiment due to its low cost. Aspheric lens 229 focuses the combined beam into an optical fiber 245 (FIG. 2D) with a diameter of at least 50 μm, 100 μm, 150 μm, or 200 μm. The fiber outputs of multiple laser diode modules 220 are combined using a fiber combiner to generate a higher output power level laser according to FIG. 1 (line 101). The laser diode module is an optical combination in which the aspheric lens 229 and fiber combiner 240 are replaced with a set of shear mirrors, which in turn couple to the aspheric lens and direct the combined beam into the end of the optical fiber. combined using methods. In this manner, one, two, three, tens, and hundreds of laser diode modules can be optically associated and their respective laser beams combined. In this way, the combined laser beam can also be combined itself or into a stack to form multiple combined laser beams.

In the embodiments of FIGS. 2C and 2D, the configuration makes it possible to launch laser beam powers of, for example, up to 200 watts into a single 50 μm, 100 μm, 150 μm, or 200 μm core optical fiber. The embodiments of FIGS. 2C and 2D show typical components for creating a 200W diode array assembly, e.g., a 200W combined module, using up to four 50W individual diode assemblies, e.g., 50W modules. .

It is understood that multiple configurations, powers, and numbers of combined beams are possible. The embodiment of FIGS. 2C and 2D minimizes electrical connections from the power supply to the laser diode.

Thus, individual modules, combination modules, and both can be configured to provide a single combined laser beam, or multiple combined laser beams, e.g. It can also be configured to provide one hundred or more combined laser beams. These laser beams may each be launched into a single fiber, or they may be further combined so that they are launched into a smaller number of fibers. Thus, by way of example, 12 combined laser beams could be launched into 12 fibers, or the 12 beams could be combined into fewer than 12 fibers, such as 10, 8, 6, 4, or It can also be injected into three fibers. This combining step can be of different powers to balance or unbalance the power distribution between the individual fibers, and can be of different wavelengths or of the same wavelength. I want to be understood as something that can be done.

In some embodiments, the brightness of an array of laser diodes can be improved by operating each array at a different wavelength and then combining them using a diffraction grating or a series of narrow band dichroic filters. The brightness scaling of this technique is shown in FIG. 1 as a near-straight line 102. The starting point is the same brightness that could be achieved by a single module, and since each module is spatially superimposed on the previous one in a linear fashion, the fiber diameter remains the same but the injected power is In fact, it results in higher brightness from the wavelength beam combining module.

In some embodiments, an array of blue laser diodes can be converted to a nearly single mode or single mode output with the help of a brightness converter. The brightness converter can be an optical fiber, a crystal, or a gas. The conversion process proceeds via stimulated Raman scattering, which is achieved by injecting the output from an array of blue laser diodes into an optical fiber, crystal, or gas using a resonator cavity. The power of the blue laser diode is converted to gain via stimulated Raman scattering, and the laser cavity oscillates on a first Stokes Raman line that is offset from the pump wavelength by a Stokes shift. For example, the embodiment shown in FIG. 3 and associated disclosure of the specification of U.S. Patent Application No. 14/787,393 is based on WO 2014/179345, the entire disclosure of which is hereby incorporated by reference. Incorporated as a reference. The performance characteristics of this technology are shown in line 103 in Figure 1, where the brightness is 0.3 mm-mrad for a 200 W laser when combining multiple high-intensity laser beams using a fiber combiner. and 2 mm-mrad for a 4000W laser.

The brightness of the blue laser light source can be further increased by combining the outputs of the brightness-converted light sources. The performance of this type of embodiment is illustrated by line 104 in FIG. Here the brightness is defined by the starting module to 0.3 mm-mrad. The gain-bandwidth of Raman lines is substantially wider than that of laser diodes, so more lasers can be coupled across wavelengths than with laser diode technology alone. The result is a 4kW laser with the same 0.3mm-mrad as a 200W laser. This is indicated by flat line 104 in FIG.

The inventive techniques described herein range from welding, cutting, brazing, heat treating, engraving, forming, forming, joining, annealing, and ablating, and combinations of these and various other material processing operations. It can be used to configure laser systems for a wide range of applications ranging from: Although the preferred laser light source is relatively high brightness, the present invention also provides the ability to configure systems that meet lower brightness requirements. Additionally, groups of these lasers can be combined into long lines that can be used to target materials, such as when annealing large area semiconductor devices such as TFTs in flat panel displays. Laser operation can be performed over a wider area.

Create unique individually addressable printing machines using the output of laser diodes, laser diode arrays, wavelength-coupled laser diode arrays, intensity-converted laser diode arrays, and wavelength-coupled laser diode arrays You can also. Because the laser power from each module is sufficient to melt and fuse metal powders as well as plastics, these sources are suitable for additive manufacturing applications as well as for additive-subtractive manufacturing applications (i.e., the present laser additive manufacturing system). It is also ideal for use in combination with CNC machines or other types of milling machines and traditional ablation manufacturing techniques such as laser ablation or ablation). The present system and laser configuration has the ability to provide small spot size, precision, and other factors for micro- and nanoscale additive, additive, and additive-subtractive manufacturing techniques. You can also find uses for it. By imaging an array of individually connected lasers onto a powder surface, objects can be created n times faster than a single scanning laser source. Speed can be further increased by using a higher power laser for each of the n spots. When using intensity-converted lasers, a near-diffraction-limited spot can be achieved for each of the n spots, so that thanks to the submicron nature of the individual spots formed using the blue high-intensity laser source, , it becomes feasible to create higher resolution parts. This smaller spot size of the present configuration and system provides substantial improvements in processing speed and resolution of the printing process compared to prior art 3D printing techniques. When embodiments of the present system are combined with a portable powder feeding device, it is possible to continuously print layer after layer at over 100 times the printing speed of prior art additive manufacturing machines. By allowing the system to deposit powder as the positioning device moves in either a positive or negative direction directly behind the laser fusion spot (e.g., FIG. 5, powder device 508, powder device 508b). , the system can print continuously without having to stop to apply or level the necessary powder for the next layer.

Turning to FIG. 3, a schematic diagram of the laser process is shown for a laser system with two rows of staggered spots, e.g. spot 303a and e.g. spot 303b. A laser spot, eg 303a, 303b, is moved, eg scanned, in the direction of arrow 301 across the target material. Assuming that the target material is in powder form 302, the material is then melted by the laser spot 304 and then solidified generally along the transition line 305 into a fused material 306. Beam power, beam irradiation time, speed of movement, and combinations thereof can be varied in a predetermined manner to yield a predetermined shape of the melting transition line 305. The distances by which the beams can be staggered are 0 mm, 0.1 mm, 0.5 mm, 1 mm, 2 mm apart, as required by the fixtures required to hold the fibers and their optical components. can be done. Further, the step difference may be a position that monotonically increases and decreases with a set step size, or a position that increases and decreases with a variable step size. The exact speed advantage will depend on the target material and configuration of the part being manufactured.

FIG. 4 summarizes the performance that can be achieved for embodiments of laser systems and configurations such as those depicted for the 20-beam system in FIGS. 5-7, where the speed increases each time an additional beam is added to the system. increases to

Turning to FIG. 5, a schematic diagram of an embodiment of a laser system having an addressable laser delivery configuration is provided. The system includes an addressable laser diode system 501. System 501 independently provides addressable laser beams to multiple fibers 502a, 502b, 502c (larger or smaller numbers of fibers and laser beams are also envisioned). Fibers 502a, 502b, 502c are combined into a fiber bundle 504 that is housed in a protection tube 503 or cover. Fibers 502a, 502b, 502c of fiber bundle 504 are fused together to form a printhead 505, which includes optical elements that focus and direct the laser beam along a beam path to a target material 507. Assembly 506 is included. The print head and powder hopper move together as the print head moves in the forward direction according to 510. Additional material 509 is deposited on top of the fused material 507 with each pass through the print head or hopper. The print head is bidirectional, fusing material in both directions as the print head moves, so the powder hopper runs behind the print head to be fused on the next pass of the laser print head. We provide laminated materials.

"Addressable array" means one or more of the following: power; duration of irradiation; sequence of irradiation; location of irradiation; power of the beam; shape of the beam spot as well as focal length, e.g. More than that, it can be independently varied, controlled and predefined, or a precise and defined delivery that allows each laser beam of each fiber to reveal a high precision end product (e.g. build material) from the target material. This means that patterns can be provided. Addressable array embodiments further provide the ability to perform variable, predetermined, and precise laser operations on the individual beams and the laser spots produced by those beams, such as annealing, ablation, and melting. can have.

Turning to FIG. 6, a schematic diagram of an embodiment of a laser system having an addressable laser delivery configuration is provided. The laser system can be a laser diode array system, a brightness conversion system, or a high power fiber laser system. The system includes an addressable laser system 601. The system 601 independently provides addressable laser beams to multiple fibers 602a, 602b, 602c (larger or smaller numbers of fibers and laser beams are also envisioned). Fibers 602a, 602b, 602c are combined into a fiber bundle 604 that is housed in a protection tube 603 or cover. Fibers 602a, 602b, 602c of fiber bundle 604 are fused together to form a printhead 605, which includes optical elements that focus and direct the laser beam along a beam path to a target material 607. Assembly 606 is included. Target material 607 can be annealed to form annealed material 609. The direction of movement of the laser head is indicated by arrow 610.

Turning to FIG. 7, a schematic diagram of an embodiment of a laser system having an addressable laser delivery configuration is provided. The system includes an addressable laser diode system 701. System 701 independently provides addressable laser beams to multiple fibers 702a, 702b, 702c (larger or smaller numbers of fibers and laser beams are also envisioned). Fibers 702a, 702b, 702c are combined into a fiber bundle 704 that is housed in a protection tube 703 or cover. Fibers 702a, 702b, 702c of fiber bundle 704 are fused together to form print head powder dispensing head 720. Powder distribution head 720 can deliver powder coaxially with the laser beam or transversely to the laser beam. Once the powder dispensing head 720 provides a layer of additional material 709, that layer is fused to and onto the target material 707. The direction of movement of the laser head is indicated by arrow 710.

FIG. 8 shows the configuration of a bundle 800 of fibers, such as 801, fused together and used in a laser head of a system such as the systems shown in FIGS. 5-7. The configuration will deliver a laser spot with a similar configuration to the fiber array. This embodiment is a 1x5 linear configuration with five fibers in a single linear row. A 1×n linear row of fibers is the ultimate laser print head, where n depends on the physical extent of the product being printed.

FIG. 9 shows the configuration of a bundle 900 of fibers, such as 901, fused together and used in a laser head of a system such as the systems shown in FIGS. 5-8. The configuration has two linear rows 902, 903 of fibers arranged in a staggered diamond-shaped arrangement. The fibers will deliver a laser spot with a configuration similar to the fiber array. This embodiment is a 2x5 linear configuration with two linear rows of five fibers in each row.

FIG. 10 shows the configuration of a bundle (1000) of fibers, eg 1001, fused together and used in the head of a system such as the systems shown in FIGS. 5-8. The configuration has three linear rows of fibers 1002, 1003, 1004 arranged in a staggered diamond-shaped arrangement. The fibers will deliver a laser spot with a configuration similar to the fiber array. This embodiment is a 3x5 linear configuration with three linear rows of five fibers in each row.

FIG. 11 shows the configuration of a bundle 1100 of fibers, such as 1101, fused together and used in the head of a system such as the systems shown in FIGS. 5-8. The configuration has three linear rows of fibers 1102, 1103, 1104 arranged in a staggered triangular arrangement. The fibers will deliver a laser spot with a configuration similar to the fiber array. This embodiment is a 3x5 linear configuration with three linear rows of five fibers in each row.

FIG. 12 shows the configuration of a bundle 1200 of fibers, such as 1201, fused together and used in the head of a system such as the systems shown in FIGS. 5-8. The configuration has four linear rows of fibers 1202, 1203, 1204, 1205 arranged in a non-staggered square arrangement. The fibers will deliver a laser spot with a configuration similar to the fiber array. This embodiment is a 4x4 linear configuration with four linear rows of four fibers in each row.

FIG. 13 shows the configuration of a bundle 1300 of fibers, such as 1301, fused together and used in the head of a system such as the systems shown in FIGS. 5-8. The configuration has five linear rows 1302 of fibers. The fibers are not staggered, but arranged in a rectangular array. The fibers will deliver a laser spot with a configuration similar to the fiber array. This embodiment is a 5x4 linear configuration with five linear rows of four fibers in each row.

FIG. 14A shows the configuration of a bundle 1401 of five (n=5) fibers, eg 1401a, arranged in a circular configuration.

FIG. 14B shows the configuration of a bundle 1402 of nine fibers (n=9), such as fibers 1402a arranged in a circular configuration and fiber 1402b located in the center of the circle. The central fibers 1402b may be held in place by a medium or holding device or otherwise fused.

FIG. 14C shows the configuration of a bundle 1403 of 19 (n=19) fibers, eg 1403a, with an inner circle fiber 1405 and a center fiber 1403b.

FIG. 15A shows a bundle 1501 of seven (n=7) fibers, eg 1501a, having a hexagonal arrangement with triangular spaces.

FIG. 15B shows a bundle 1502 of 19 (n=19) fibers, eg 1502a, having a hexagonal arrangement with triangular spacing.

16A, 16B, and 16C illustrate configurations of fiber bundles arranged in arbitrary geometries. These configurations offer various levels of fiber density within the configuration. FIG. 16A shows a bundle 1601 of n=16 fibers in a quarter circle configuration, for example 1601a. FIG. 16B is a bundle 1602 of n=8 fibers, eg 1602b, in a rectangular configuration. FIG. 16C is a bundle 1604 of n=6 fibers, eg 1604a, in a triangular configuration. FIG. 16D shows a bundle 1603 of n=9 fibers, eg 1603a, in a semicircular configuration.

The following examples are provided to illustrate various embodiments of the laser arrays, systems, devices, and methods of the present invention. These examples are for illustrative purposes and are not to be considered or otherwise limit the scope of the invention.

Example 1
An array of blue laser diodes spatially coupled to form a single spot in the far field and capable of being coupled into a solarization-resistant optical fiber for delivery to the workpiece.

Example 2
An array of blue laser diodes as described in Example 1, wherein the array of blue laser diodes is a polarized beam combined to increase the effective brightness of the laser beam.

Example 3
an array of blue laser diodes having a space between each of the collimated beams in the fast axis of the laser diodes, reflecting a first laser diode(s) and reflecting a second laser diode(s); ) An array of blue laser diodes combined with a periodic plate for transmitting the laser diodes to fill the space between the laser diodes in the fast axis direction of the first array.

Example 4
Patterned mirror on glass substrate used to achieve space filling in Example 3.

Example 5
Patterned mirror on one side of a glass substrate to achieve space filling in Example 3, wherein the glass substrate shifts the vertical position of each laser diode to create a space between individual laser diodes. A patterned mirror that is thick enough to fill the space.

Example 6
A stepped heat sink that achieves the space filling of Example 3 and is a patterned mirror as described in Example 4.

Example 7
In the array of blue laser diodes described in Example 1, each of the individual lasers is tuned by an external cavity to a different wavelength to substantially increase the brightness of the array to a brightness comparable to a single laser diode source. An array of blue laser diodes that is locked.

Example 8
In the array of blue laser diodes described in Example 1, the individual arrays of laser diodes are locked to a single wavelength using an external cavity based on a diffraction grating, and each of the laser diode arrays is An array of blue laser diodes that are combined into a single beam using either a filter or a diffraction grating.

Example 9
An array of blue laser diodes as described in Example 1 with a pure fused silica core to reveal a higher brightness light source and a fluorinated outer core to house the blue pump light. An array of blue laser diodes used to pump a Raman converter such as an optical fiber with.

Example 10
An array of blue laser diodes as described in Example 1, with a GeO2-doped central core and an outer core to reveal a higher brightness light source and a central core to house the blue pump light. An array of blue laser diodes used to pump a Raman converter, such as an optical fiber, with a larger outer core.

Example 11
An array of blue laser diodes as described in Example 1, with a P2O5 doped core to reveal a higher brightness light source and an outer core larger than the central core to accommodate the blue pump light. and an array of blue laser diodes used to pump a Raman converter such as an optical fiber.

Example 12
An array of blue laser diodes as described in Example 1, with a graded-index core to reveal a higher brightness light source and an outer core larger than the central core to accommodate blue pump light. and an array of blue laser diodes used to pump a Raman converter such as an optical fiber.

Example 13
An array of blue laser diodes as described in Example 1, with a graded-index GeO2-doped core and an outer step-index core, the blue laser used to pump the Raman converter fiber. array of diodes.

Example 14
An array of blue laser diodes as described in Example 1, with a graded-index P2O5 doped core and an outer step-index core, the blue laser used to pump the Raman converter fiber. array of diodes.

Example 15
An array of blue laser diodes as described in Example 1 and used to pump a graded-index GeO2-doped core Raman converter fiber.

Example 16
An array of blue laser diodes as described in Example 1, with a graded-index P2O5 doped core and an outer step-index core, the blue laser used to pump the Raman converter fiber. array of diodes.

Example 17
Other embodiments of Example 1 and variations of the embodiments of Example 1 are envisioned. An array of blue laser diodes as described in Example 1 and used to pump a Raman converter such as a diamond to develop a higher brightness laser light source. An array of blue laser diodes as described in Example 1 and used to pump a Raman converter such as a KGW to develop a higher brightness laser light source. An array of blue laser diodes as described in Example 1 and used to pump a Raman converter such as YVO4 to develop a higher brightness laser light source. An array of blue laser diodes as described in Example 1, wherein the blue laser is used to pump a Raman converter such as Ba(NO3)2 to develop a higher brightness laser light source. array of diodes. An array of blue laser diodes as described in Example 1 and used to pump a Raman converter with high pressure gas to bring out a higher brightness laser light source. An array of blue laser diodes as described in Example 1 and used to pump a rare earth doped crystal to develop a higher brightness laser light source. An array of blue laser diodes as described in Example 1 and used to pump a rare earth doped fiber to develop a higher brightness laser light source. An array of blue laser diodes as described in Example 1 and used to pump the outer core of a brightness converter to develop a higher brightness enhancement ratio.

Example 18
An array of Raman conversion lasers operating at individual wavelengths that are combined to reveal a higher power light source while maintaining the spatial brightness of the original light source.

Example 19
Raman fibers with dual cores and filters, fiber Bragg gratings, V-number differences for the first and second order Raman signals, or microbends to suppress the second order Raman signals of the high brightness central core. The difference in loss between the means using and the Raman fiber.

Example 20
N laser diodes, with N≧1, which can be turned on and off individually and imaged onto a powder bed to melt and fuse the powder into a unique component.

Example 21
N laser diode array of Example 1, with N≧1, the output of which can be fiber coupled, each fiber imaging or focusing onto the powder to form the powder into a uniquely shaped stack. A laser diode array that can be arranged in a linear or nonlinear manner to reveal an addressable array of high power laser beams that can be melted or fused.

Example 22
One or more laser diode arrays combined via a Raman converter, the output of which can be fiber-coupled, each fiber imaging or focusing onto the powder to uniquely One that can be arranged in a linear or non-linear fashion to reveal an addressable array of N that can be melted or fused into a stack of shapes, where N≧1. Or more laser diode arrays.

Example 23
An xy motion system capable of melting and merging a powder bed while moving an N blue laser light source across the powder bed, with N≧1, adding an additional powder layer behind the fused layer. An xy motion system having a powder delivery system positioned behind a laser light source to provide an xy motion system.

Example 24
A z-motion system capable of increasing/decreasing the height of the part/powder bed of Example 20 after a new powder bed is placed.

Example 25
A z-motion system capable of increasing/decreasing the height of the part/powder of Example 20 after the powder layer is fused by a laser light source.

Example 26
A two-way powder placement capability for Example 20, in which the powder is placed directly behind the laser spot(s) as the laser spot(s) travels in the positive x direction or the negative x direction.

Example 27
A two-way powder placement capability for Example 20, in which the powder is placed directly behind the laser spot(s) as the laser spot(s) travels in the positive y direction or the negative y direction.

Example 28
Powder feeding system that is coaxial with the N laser beam as N≧1.

Example 29
In a powder feeding system, the powder is fed by gravity.

Example 30
A powder feeding system in which the powder is entrained in a flow of inert gas.

Example 31
A powder feeding system transverse to N laser beams, with N≧1, the powder being placed directly in front of the laser beam by gravity.

Example 32
A powder feeding system, the powder feeding system being transverse to a laser beam of N, with N≧1, the powder being entrained in a flow of inert gas intersecting the laser beam.

Example 33
For example, a second harmonic generation system that uses the output of a 460 nm Raman converter to generate light at half the wavelength of the source laser, ie, 230 nm, and is made of an externally resonant doubling crystal such as KTP. A second harmonic generation system that does not allow short wavelength light to propagate through the optical fiber.

Example 34
A third harmonic generation system in which, for example, the output of a 460 nm Raman converter is used to generate 115 nm light using an externally resonant doubling crystal, but the shorter wavelength light is passed through an optical fiber. Third harmonic generation system that does not allow transmission.

Example 35
A fourth harmonic generation system, for example, using the output of a 460 nm Raman converter to generate 57.5 nm light using an externally resonant doubling crystal, where the shorter wavelength light passes through an optical fiber. A fourth harmonic generation system that does not allow propagation through the system.

Example 36
A second harmonic generation system uses the output of a rare-earth-doped brightness converter, such as thulium, that emits a 473-nm laser when pumped by an array of 450-nm blue laser diodes to generate half of the source laser. A second harmonic generation system that generates light at a wavelength of 236.5 nm using an externally resonant doubling crystal, but does not allow shorter wavelength light to propagate through the optical fiber.

Example 37
A third harmonic generation system that produces 118.25 nm light using the output of a thulium-like rare earth doped brightness converter that emits a 473 nm laser when pumped by an array of 450 nm blue laser diodes. A third harmonic generation system that uses an externally resonant doubling crystal to generate a third harmonic, but does not allow shorter wavelength light to propagate through the optical fiber.

Example 38
A fourth harmonic generation system uses the output of a rare earth-doped brightness converter, such as thulium, to emit a 473 nm laser when pumped by an array of 450 nm blue laser diodes to produce 59.1 nm light. A fourth harmonic generation system that uses an externally resonant doubling crystal, but does not allow short wavelength light to propagate through the optical fiber.

Example 39
All other rare earth doped fibers and crystals that can be pumped by a high power 450 nm light source to produce visible or near visible output may be used in Examples 34-38.

Example 40
Injection of high power visible light into the non-circular outer core or cladding to pump the inner core of a Raman or rare earth doped core fiber.

Example 41
Use of polarization-sustaining fibers to enhance the gain of Raman fibers by aligning the pump polarization with that of the Raman oscillator.

Example 42
An array of blue laser diodes as described in Example 1, wherein the blue laser diodes are used to pump a Raman converter, such as an optical fiber, configured to reveal a higher intensity light source of a particular polarization. array of.

Example 43
Pumping a Raman converter, such as an array of blue laser diodes as described in Example 1, in a fiber optic structure that reveals a higher intensity light source of a particular polarization and sustains the polarization state of the pump source. An array of blue laser diodes used to

Example 44
An array of blue laser diodes as described in Example 1 pumping a Raman converter such as an optical fiber to reveal a high brightness light source with a non-circular outer core structured to improve Raman conversion efficiency. An array of blue laser diodes used in.

Example 45
Embodiments of Examples 1 through 44 further provide one or more of the following components or assemblies: at the end of each pass prior to the step in which the laser scans across the powder bed. equipment for leveling the powder; equipment for scaling the output power of the laser to reveal a beam of higher power output by combining multiple low power laser modules via a fiber combiner; Apparatus for scaling the output power of a blue laser module to reveal a beam of higher power output by combining power laser modules through free space; multiple lasers on a single base plate with embedded cooling It may include one or more of: a device for combining modules;

Requirements for providing or addressing the theory underlying novel and innovative performance or other advantageous features and properties that are the subject matter of or associated with embodiments of the invention. I would like to point out that there is no. Nevertheless, various theories are provided herein to further advance the technology in this important field, specifically the important field of lasers, laser processing, and laser applications. These theories proposed herein, unless expressly stated otherwise, in no way limit, limit, or narrow the scope of the claimed invention to which protection is to be afforded. isn't it. These theories may not be required or practiced in utilizing the present invention. It should be further understood that the invention relies on new and heretofore unknown theories to explain the operation, functionality, and features of embodiments of the methods, articles, materials, devices, and systems of the invention. Such subsequent theories do not limit the scope of the invention to which protection is afforded.

The various embodiments of lasers, diodes, arrays, modules, assemblies, activities, and operations presented herein can be used in the fields identified above and in various other fields. In addition, these embodiments can be applied to, for example, existing lasers, additive manufacturing systems, operations, and activities, as well as other existing equipment; future lasers, additive manufacturing systems, operations, and activities; It may also be used with such items with partial modifications based on the teachings. Furthermore, the various embodiments presented herein may be used in various combinations with each other. Thus, for example, configurations provided in various embodiments herein may be used in conjunction with each other, and the scope of the invention to be afforded protection may vary from particular embodiments to particular implementations. There is no intention to be limited to the specific implementations, configurations, or arrangements shown in the examples or embodiments in particular figures.

The present invention may be embodied in other forms than those specifically disclosed herein without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects as illustrative only and not limiting.

100 Laser Performance Graphs 101 Performance of an Embodiment of a Laser Diode Array 102 Performance of Dense Wavelength Beam Combining Arrays 103 Performance of Intensity Conversion Techniques When Scaled Using Fiber Combiner Techniques 104 Dense Wavelength Combining of Power in Intensity Converters Performance of brightness conversion technology when using 200 Laser diode 201 Fast axis collimating lens 202 Collimating lens 203 Laser beam spot 210, 210a, 210b, 210c Laser diode subassembly 211 Base plate 212 Power lead 213 Diode 214 Slow axis 216 Row 220 Laser diode module 225 Patterned mirror 227 Polarizing beam folding assembly 228 Telescope assembly 229 Aspheric lens 230, 231, 232, 233, 234 Beam 235 Aperture stop 240 Fiber combiner 245 Optical fiber 250a, 251a, 252a Laser beam 250, 251, 252 Laser beam path 260 Horizontal direction of open space 261 Vertical direction of open space 301 Direction of movement of laser spot 303a, 303b, 304 Laser spot 305 Melting transition line 306 Fusion material 500 Laser system 501 Addressable laser diode system 502a, 502b, 502c fibers 503 protection tube 504 fiber bundle 505 print head 506 optics assembly 507 target material 508, 508b powder device 509 additional material 510 direction of print head movement 600 laser system 601 addressable laser system 602a, 602b , 602c fiber 603 protection tube 604 fiber bundle 605 print head 606 optics assembly 607 target material 609 annealing material 610 direction of print head movement 700 laser system 701 addressable laser diode system 702a, 702b, 702c fiber 704 fiber bundle 707 target Material 709 Layer of additional material 710 Direction of movement of print head 720 Powder distribution head 800 Fiber bundle 801 Fiber 900 Fiber bundle 901 Fiber 902, 903 Linear row 801 Fiber 1000 Fiber bundle 1002, 1003, 1004 Linear row 1100 Fiber bundle 1101 Fiber 1102, 1103, 1104 Linear row 1200 Fiber bundle 1201 Fiber 1202, 1203, 1204, 1205 Linear row 1300 Fiber bundle 1301 Fiber 1302 Linear row 1401 Fiber bundle 1401a Fiber 1402 Fiber bundle 1402a, 1402b Fiber 1403 Fiber bundle 140 3a, 1403b, 1405 fiber 1501 fiber Bundle 1501a Fiber 1502 Fiber bundle 1502a Fiber 1601 Fiber bundle 1601a Fiber 1602 Fiber bundle 1602a Fiber 1603 Fiber bundle 1603a Fiber 1604 Fiber bundle 1604a Fiber

Claims (12)

An addressable array laser processing system comprising at least three laser systems, each laser system comprising:
a. at least three laser diode assemblies,
b. each of the at least three at least laser diode assemblies comprising at least ten laser diodes, each of the at least ten laser diodes having a power of at least about 2 Watts and a blue laser having a beam parameter product of less than 8 mm-mrad; The beams may be generated along laser beam paths, each laser beam path being essentially parallel, such that a space is defined between the blue laser beams traveling along the laser beam paths. three laser diode assemblies,
c. means for spatially coupling the blue laser beam to maintain the brightness of the blue laser beam, the means being disposed in all of at least 30 of the laser beam paths, the means for spatially combining the blue laser beam to maintain the brightness of the blue laser beam; a vertical prism array for a second axis of the laser beam, and a telescope, whereby the means for maintaining spatial coupling of the blue laser beam means for filling the space between with laser energy, thereby providing a combined laser beam having a power of at least about 250 Watts and a beam parameter product of less than 40 mm-mrad;
d. Each of the at least three laser systems is configured to couple each of the combined laser beams into a single optical fiber, such that each of the at least three combined laser beams is transmitted along the combined optical fiber. wherein the at least three optical fibers are optically associated with a laser head and a control system for delivering each of the combined laser beams to a predetermined location on the target material. An addressable array laser processing system having a program having a predetermined sequence of. The predetermined sequence for delivery individually turns on and off the blue laser beam from the laser head, thereby imaging it onto a powder bed to melt and fuse the target material with powder into a part. 2. The addressable array laser processing system of claim 1, comprising steps. 2. The addressable array laser of claim 1, wherein the optical fibers in the laser head are configured in an arrangement selected from the group consisting of linear, nonlinear, circular, rhombic, square, triangular, and hexagonal. processing system. Addressable according to claim 1, wherein the optical fibers in the laser head are arranged in an arrangement selected from the group consisting of 2x5, 5x2, 4x5, at least 5xat least 5, 10x5, 5x10, and 3x4. Array laser processing system. The target material has a powder bed, and the addressable array laser processing system further includes an x-y laser head capable of moving the laser head across the powder bed, thereby melting and fusing the powder bed. The addressable array laser processing system of claim 1, comprising a motion system and a powder delivery system positioned behind the laser light source to provide an additional powder layer behind the fused layer. 6. The addressable array laser processing system of claim 5, comprising a z-motion system capable of moving the laser head to increase and decrease the height of the laser head above the surface of the powder bed. 6. The addressable array of claim 5, comprising a two-way powder placement device capable of placing powder directly behind the delivered blue laser beam as it travels in the positive x direction or the negative x direction. Laser processing system. 6. The addressable array laser processing system of claim 5, comprising a powder feeding system coaxial with the plurality of laser beam paths. 6. The addressable array laser processing system of claim 5, comprising a gravity powder feeding system. 6. The addressable array laser processing system of claim 5, comprising a powder delivery system in which the powder is entrained in a flow of inert gas. 5. A powder feeding system transverse to the blue laser beam of N, wherein N≧1, the powder feeding system being placed in front of the blue laser beam by gravity. Addressable array laser processing system described in . a powder feeding system transverse to a blue laser beam of N, with N≧1, such that the powder is entrained in a flow of inert gas intersecting the blue laser beam; , the addressable array laser processing system of claim 5.

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