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Multiple beams and nozzles to increase deposition rate
| Details |
Inventors: Keicher, David M.; Miller, W. Doyle;
Assignee: Optomec Design Company (Albuquerque, NM)
Primary Examiner: Evans; Geoffrey S.
Assistant Examiner:
Attorney, Agent or Firm: Gray Cary Ware & Freidenriche LLP, Haile; Lisa A.
A method has been developed to exploit the desirable material and process characteristics provided by a low powered laser material deposition system, while overcoming the low material deposition rate imposed by the same process. One application of particular importance for this invention is direct fabrication of functional, solid objects from a CAD solid model. This method of fabrication uses a software interpreter to electronically slice the CAD model into thin horizontal layers that are subsequently used to drive the deposition apparatus. The apparatus uses a single laser beam to outline the features of the solid object and then uses a series of equally spaced laser beams to quickly fill in the featureless regions. Using the lower powered laser provides the ability to create a part that is very accurate, with material properties that meet or exceed that of a conventionally processed and annealed specimen of similar composition. At the same time, using the multiple laser beams to fill in the featureless areas allows the fabrication process time to be significantly reduced. |
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DETAILED DESCRIPTION OF THE INVENTION A schematic of the preferred embodiment of this invention is given in FIG.
1, showing the position of the invention within a direct material deposition system.
The system includes: a powder feeding apparatus 10, to deliver a uniform flow of powder to the deposition region; a laser 12, to cause heating and subsequent melting of the powder feed particles; and a deposition head/heads 36.
The system also includes a set of orthogonal positioning stages 26, which are computer driven to direct the location of deposition; a vertical stage 14; a computer 32, on which software 34 is used to slice the CAD solid models and generate a motion control program to control deposition processing sequence based on CAD file data; and a sealed chamber 20, to contain the powder particles during processing and provide an inert environment.
Referring to FIGS.
2A and 2B the multi beam deposition apparatus begins with four beam delivery fibers 38, that are equally spaced apart at a prescribed distance 16, which are used to transport the laser beams to the deposition apparatus.
The beams out of the fiber are divergent laser beams 40 and transmitted through the spherically shaped collimating lens 42.
The laser beams then leave the collimating lens 42 as collimated laser beams 44 located above the deposition head 36.
These collimated laser beams 44 are then transmitted through a second spherically shaped focusing lens 46 to be focused onto the deposition substrate 58.
The focused laser beams 50 create a linear array of focused laser spots 15 on the deposition substrate 58.
The focus plane 18 of the focused laser spots is located at/or near the deposition substrate, which is also the same as the deposition substrate 58.
This spacing between the focused laser spots 17 is dictated by the prescribed distance 16 between the beam delivery fibers 38 and the magnification provided by the imaging system created by the combination of the collimating lens 42 and the focusing lens 46.
For this configuration, the deposition head is conical in shape
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MEMS 
