IP Verse

Visible Laser Additive Manufacturing

Patent No. US11980970 (titled "Visible Laser Additive Manufacturing") was filed by Blue 425 Llc on Apr 28, 2017.

What is this patent about?

’970 is related to the field of laser processing of materials , specifically laser additive manufacturing. Traditional infrared (IR) laser-based additive manufacturing systems face limitations in build volume and speed due to the relatively large spot size achievable with IR wavelengths and the modest absorption of IR light by many raw materials. This results in a limited addressable footprint and restricts layer thickness, ultimately impacting resolution.

The underlying idea behind ’970 is to improve the efficiency and resolution of laser additive manufacturing by using a blue laser (wavelengths between 400 nm and 500 nm). The key inventive insight is that blue lasers offer better absorption characteristics for many materials compared to IR lasers, and can be focused to a smaller spot size for a given lens system. This allows for a larger addressable field and finer layer resolution, leading to improved build volume and part quality.

The claims of ’970 focus on a blue laser system for additive manufacturing. The system includes a blue laser source, an X-Y scanning system to direct the laser beam, an enclosure housing the build area, and an electronically adjustable lens system. This lens system, comprising three optics with a movable second optic, enables on-the-fly focusing to simulate the performance of an F-Theta lens, allowing for precise control of the laser spot size and position.

In practice, the system uses the electronically adjustable lens system to dynamically focus the blue laser beam as it scans across the build area. By moving the second lens, the system can compensate for field curvature and adjust the beam diameter on the fly. This allows the system to maintain a consistent spot size and energy density across the entire addressable field, improving the uniformity and precision of the additive manufacturing process. A controller monitors and adjusts laser power, scanning speed, and spot size based on feedback from sensors like pyrometers or thermal cameras, ensuring optimal weld puddle temperature and size.

The use of a blue laser offers several advantages over traditional IR systems. The smaller spot size allows for higher resolution and finer details in the manufactured parts. The improved absorption of blue light by materials like gold, copper, and nickel leads to more efficient energy coupling and reduced risk of runaway processes. Furthermore, the system can achieve a significantly larger addressable field compared to IR systems with the same spot size, enabling the production of larger parts or higher throughput. The system can also be used for remote welding, cutting, and soldering applications.

How does this patent fit in bigger picture?

Technical landscape at the time

In the mid-2010s when '970 was filed, additive manufacturing systems commonly relied on infrared lasers, at a time when the build volume was typically limited by the scanning system size and achievable spot size. At that time, the absorption characteristics of raw build materials for infrared wavelengths presented a challenge, where a significant portion of the laser energy was reflected, limiting the energy coupling and build speed.

Novelty and Inventive Step

The examiner approved the application because the prior art, whether considered individually or in combination, did not disclose the specific structural and functional characteristics defined in the claims. Specifically, the prior art did not disclose a blue laser system that includes a blue laser source, an X-Y scanning system with an enclosure for the addressable field, and an electronically adjustable lens system with three optics where the second optic is positioned along the laser beam path between the first and third optics and is movable to allow on-the-fly focusing that simulates an F-Theta lens. Also, the prior art did not disclose a blue laser system with the same components where the addressable field is twice as large as that of an infrared laser system with the same spot size.

Claims

This patent contains 13 claims, with claims 1 and 6 being independent. The independent claims are directed to a blue laser system that includes a blue laser source, an X-Y scanning system, an enclosure, and an electronically adjustable lens system configured for on-the-fly focusing. The dependent claims generally elaborate on the features and capabilities of the blue laser system described in the independent claims, such as addressable field dimensions, laser operations, and control systems for maintaining weld puddle temperature and size.

Key Claim Terms New

Definitions of key terms used in the patent claims.

Term (Source)Support for SpecificationInterpretation
Addressable field
(Claim 1, Claim 6)		“Thus, there is provided a blue laser system, the system having: a blue laser source capable of propagating a blue laser beam; an X-Y scanning system in optical communication with the blue laser source, whereby the system is capable of directing and scanning the blue laser beam to an addressable field; and an enclosure housing the addressable field.”The area or volume to which the blue laser beam is directed and scanned.
Blue laser beam spot size
(Claim 6)		“Yet further there is provided a blue laser system, the system having: a blue laser source capable of propagating a blue laser beam; an X-Y scanning system in optical communication with the blue laser source, whereby the system is capable of directing and scanning the blue laser beam along a laser beam path to an addressable field; and an enclosure housing the addressable field; an electronically adjustable lens system; the lens system having a first optic, a second optic, and a third optic, wherein the second optic is located along a laser beam path between the first optic and the third optic; wherein the second optic is movable between a plurality of positions along the laser beam path; whereby the system is capable of focusing the blue laser beam to a spot, having a blue laser beam spot size; whereby the addressable field defines an area; whereby the area of the addressable field is 2× larger than an area of an addressable field for an infrared laser beam having an infrared laser beam spot size that is the same size as the blue laser beam spot size and that is propagated through the system along the same laser beam path.”The size of the spot to which the blue laser beam is focused.
Blue laser source
(Claim 1, Claim 6)		“As used herein, unless expressly stated otherwise, the terms “blue laser beams”, “blue lasers” and “blue” should be given their broadest meaning, and in general refer to systems that provide laser beams, laser beams, laser sources, e.g., lasers and diodes lasers, that provide, e.g., propagate, a laser beam, or light having a wavelength from about 400 nm to about 500 nm.”A laser source that emits a blue laser beam.
Electronically adjustable lens system
(Claim 1, Claim 6)		“Moreover there are provided these systems, apparatus and methods having one or more of the following features: having an electronically adjustable lens system; the lens system having a first optic, a second optic, and a third optic, wherein the second optic is located along a laser beam path between the first optic and the third optic, wherein the second optic is movable between a plurality of positions along the laser beam path, whereby the system is capable of on the fly focusing to simulate the performance of an F-Theta lens; having an F-Theta lens, and an electronically adjustable lens system; the lens system having a first optic, a second optic, and a third optic, wherein the second optic is located along a laser beam path between the first optic and the third optic, wherein the second optic is movable between a plurality of positions along the laser beam path, whereby the lens system is capable of compensating for the field curvature of an F-Theta lens system; and having an electronically adjustable lens system; the lens system having a first optic, a second optic, and a third optic, wherein the second optic is located along a laser beam path between the first optic and the third optic, wherein the second optic is movable between a plurality of positions along the laser beam, whereby the system is capable of adjusting the laser beam diameter on the fly as the laser beam is scanned.”A lens system with optics that can be moved to adjust the focus and/or beam diameter of the laser beam.
X-Y scanning system
(Claim 1, Claim 6)		“Thus, there is provided a blue laser system, the system having: a blue laser source capable of propagating a blue laser beam; an X-Y scanning system in optical communication with the blue laser source, whereby the system is capable of directing and scanning the blue laser beam to an addressable field; and an enclosure housing the addressable field.”A system that directs and scans the blue laser beam to an addressable field.

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US11980970

BLUE 425 LLC
Application Number
US15581494
Filing Date
Apr 28, 2017
Status
Granted
Expiry Date
Apr 11, 2038
External Links
Slate, USPTO, Google Patents