Apparatus and method for the additive manufacturing of three-dimensional structures

Patent metadata

Field	Value
Publication number	US-11207735-B2
Application number	US-201916267475-A
Country	US
Kind code	B2
Filing date	Feb 5, 2019
Priority date	Feb 7, 2018
Publication date	Dec 28, 2021
Grant date	Dec 28, 2021

Abstract

An apparatus for the additive manufacturing of three-dimensional structures from a material that is to be solidified by way of location-selective solidification thereof as a result of light-induced chemical and/or physical processes in the material includes a laser source for producing a laser beam, a focusing optical unit for focusing the laser beam so as to form a laser focus, and a beam-splitter optical unit for splitting the laser beam into at least two partial laser beams. The laser source, the focusing optical unit and the beam-splitter optical unit are arranged such that the laser beam, starting from the laser source, passes first through the focusing optical unit and then through the beam-splitter optical unit and the partial laser beams finally are each directed to different locations on the material that is to be solidified.

First claim

What is claimed is:

1. An apparatus for the additive manufacturing of three-dimensional structures from a material that is to be solidified by way of location-selective solidification thereof as a result of light-induced chemical and/or physical processes in the material, the apparatus comprising:
a laser source for producing a laser beam;
a focusing optical unit for focusing the laser beam so as to form a laser focus; and
a beam-splitter optical unit configured to split the laser beam into at least two partial laser beams, wherein the laser source, the focusing optical unit and the beam-splitter optical unit are arranged such that the laser beam, starting from the laser source, passes first through the focusing optical unit and then through the beam-splitter optical unit and the partial laser beams are each directed to different locations on the material that is to be solidified.

2. The apparatus according to claim 1 further comprising a scanner optical unit for spatially deflecting the laser beam produced by the laser source, wherein the scanner optical unit is arranged in a beam path of the laser beam between the laser source and the focusing optical unit.

3. The apparatus according to claim 1 , wherein the beam-splitter optical unit has at least one partially transmissive optical element for splitting the laser beam into at least two partial laser beams.

4. The apparatus according to claim 3 , wherein the beam-splitter optical unit has at least one optical deflection element for at least one change in direction of at least one of the partial laser beams.

5. The apparatus according to claim 4 , wherein the at least one optical deflection element is arranged and oriented such that all partial laser beams produced by the beam-splitter optical unit travel the same path length starting from the at least one partially transmissive optical element to a point of incidence on the material to be solidified.

6. A method for the additive manufacturing of three-dimensional structures from a material that is to be solidified by way of location-selective solidification thereof as a result of light-induced chemical and/or physical processes in the material, the method comprising:
irradiating the material with a laser beam produced by an apparatus comprising:
a laser source for producing the laser beam;
a focusing optical unit for focusing the laser beam so as to form a laser focus; and
a beam-splitter optical unit configured to split the laser beam into at least two partial laser beams, wherein the laser source, the focusing optical unit and the beam-splitter optical unit are arranged such that the laser beam, starting from the laser source, passes first through the focusing optical unit and then through the beam-splitter optical unit and the partial laser beams are each directed to different locations on the material that is to be solidified,
wherein the laser beam is guided starting from the laser source first to the focusing optical unit for focusing the laser beam to form the laser focus and is subsequently guided through the beam-splitter optical unit for splitting the laser beam into the at least two partial laser beams, which are finally directed in each case to the different locations on the material that is to be solidified.

7. The method according to claim 6 , wherein the laser beam produced by the laser source is spatially deflected by way of a scanner optical unit arranged in a beam path of the laser beam between the laser source and the focusing optical unit.

8. The method according to claim 6 , wherein the laser beam that has been guided to the beam-splitter optical unit is split into at the least two partial laser beams using at least one partially transmissive optical element.

9. The method according to claim 6 , wherein at least one of the at least two partial laser beams produced by the beam-splitter optical unit is deflected at least once in terms of its direction using at least one optical deflection element before it is incident on the material that is to be solidified.

10. The method according to claim 6 , wherein the at least two partial laser beams are deflected at least once in terms of their directions such that all partial laser beams produced by the beam-splitter optical unit travel the same path length starting from the at least one partially transmissive optical element to points of incidence on the material to be solidified.

11. An apparatus for the additive manufacturing of three-dimensional structures from a material that is to be solidified by way of location-selective solidification thereof as a result of light-induced chemical and/or physical processes in the material, the apparatus comprising:
a laser source for producing a laser beam;
a focusing optical unit for focusing the laser beam so as to form a laser focus;
a beam-splitter optical unit configured to split the laser beam into at least two partial laser beams, wherein the laser source, the focusing optical unit and the beam-splitter optical unit are arranged such that the laser beam, starting from the laser source, passes first through the focusing optical unit and then through the beam-splitter optical unit and the partial laser beams are each directed to different locations on the material that is to be solidified; and
a scanner optical unit for spatially deflecting the laser beam produced by the laser source, wherein the scanner optical unit is arranged in a beam path of the laser beam between the laser source and the focusing optical unit.

12. The apparatus according to claim 11 , wherein the beam-splitter optical unit has at least one partially transmissive optical element for splitting the laser beam into the at least two partial laser beams.

13. The apparatus according to claim 12 , wherein the at least one partially transmissive optical element is at least one of a locationally fixed splitter mirror and a locationally fixed optical splitter prism.

14. The apparatus according to claim 11 , wherein the beam-splitter optical unit has at least one optical deflection element for at least one change in direction of at least one of the partial laser beams.

15. The apparatus according to claim 14 , wherein the at least one optical deflection element is arranged and oriented such that all partial laser beams produced by the beam-splitter optical unit travel the same path length starting from the at least one partially transmissive optical element to points of incidence on the material to be solidified.

16. The apparatus according to claim 11 , wherein the beam splitter optical unit has at least three partially transmissive optical elements for splitting the laser beam into at least four partial laser beams.

17. The apparatus according to claim 16 , wherein each of the at least three partially transmissive optical elements is at least one of a locationally fixed splitter mirror and a locationally fixed optical splitter prism.

Assignees

• Ford Global Tech Llc

Inventors

• Koch Raphael
• Bognar Lars

Classifications

• B22F12/67

  Blades · CPC title

• B22F12/49

  Scanners · CPC title

• B22F12/45

  Two or more · CPC title

• B22F12/41

  characterised by the type, e.g. laser or electron beam · CPC title

• B22F12/38

  Housings, e.g. machine housings · CPC title