Laser cutting

Patent metadata

Field	Value
Publication number	US-2016332255-A1
Application number	US-201615218778-A
Country	US
Kind code	A1
Filing date	Jul 25, 2016
Priority date	Sep 21, 2011
Publication date	Nov 17, 2016
Grant date	—

Abstract

Laser cutting systems and methods are described herein. One or more systems include a laser generating component, an optical component, a fixture for holding a support with a part positioned on the support, and a control mechanism for adjusting at least one of the laser generating component, the optical component, and the fixture such that a ratio of a laser energy applied to the part and a part material thickness is maintained within a predetermined acceptable range at each point along a cut path to cut through the part while maintaining the integrity of the support. Other systems and methods are disclosed herein.

First claim

1 . A laser cutting system, comprising:
a laser generating component; an optical component; a fixture for holding a support with a part positioned on the support and wherein the part and support are made from different materials that are each capable of being cut by a laser; at least one control mechanism for adjusting at least one of the laser generating component, the optical component, and the fixture such that a ratio of a laser energy applied to the part is maintained within a predetermined acceptable range at each point along a cut path at which the laser contacts the part to cut through the part thickness such that the different materials do not mix; and one or more nozzles directed at the point at which the laser contacts the part.

2 . The system of claim 1 , wherein the one or more nozzles include a gas nozzle.

3 . The system of claim 2 , wherein the gas nozzle is a gas dispensing nozzle, and wherein the gas dispensing nozzle is oriented at an angle relative to the direction of the laser.

4 . The system of claim 1 , wherein the one or more nozzles include a suction mechanism located proximate to the point at which the laser contacts the part to remove debris created when the laser energy contacts the part.

5 . The system of claim 1 , wherein the control mechanism for the fixture control is configured to:
adjust a speed of the fixture, wherein the control mechanism receives data regarding the part material thickness at multiple points along a cut path where the laser beam will cut the part; and adjust a speed of movement of the part relative to the laser beam based on the thickness data such that the ratio of the laser energy applied to the part and the part material thickness is maintained within the predetermined acceptable range.

6 . The system of claim 1 , wherein the control mechanism includes a laser power adjustment control configured to:
receive data regarding the part material thickness at multiple points along the cut path where the laser beam will cut the part; and adjust a power of the laser beam based on the thickness data such that the ratio of the laser energy applied to the part and the part material thickness is maintained within the predetermined acceptable range.

7 . The system of claim 1 , wherein the control mechanism includes an optics control configured to:
adjust a position of one or more of the number of optical components, wherein the control mechanism receives data regarding the part material thickness at multiple points along a cut path where the laser beam will cut the part; and adjust a position of the one or more of the number of optical components based on the thickness data such that the ratio of the laser energy applied to the part and the part material thickness is maintained within the predetermined acceptable range.

8 . The system of claim 1 , wherein the fixture is moveable relative to the cutting position of the laser beam in at least three axes of movement.

9 . A method of laser cutting, comprising:
creating, via a computing device, a virtual version of a specialized mold and a specialized part formed on the mold; defining, via a computing device, a virtual cut path at which a laser generating component will direct energy to cut the specialized part formed on the mold; determining, via a computing device, multiple part material thickness estimates for multiple points along the virtual cut path; defining a set of adjustment instructions for adjusting at least one of the laser generating component, an optical component, and a fixture that holds the specialized mold with the specialized part formed thereon; executing the instructions via a computing device, such that a ratio of a laser energy applied to the specialized part and the specialized part material thickness is maintained within a predetermined acceptable range at each point along an actual cut path to cut through the part while maintaining the integrity of the mold; blowing gas, via a gas dispensing nozzle, at a point at which the laser contacts the specialized part to blow debris of the specialized part from the cut path; and removing the debris via a suction mechanism located proximate to the point at which the laser contacts the specialized part.

10 . The method of claim 9 , wherein blowing gas via the gas dispensing nozzle includes blowing chilled gas at the point at which the laser contacts the specialized part to cool the specialized part.

11 . The method of claim 9 , wherein blowing gas via the gas dispensing nozzle includes blowing heated gas at the point at which the laser contacts the specialized part to heat the specialized part.

12 . The method of claim 9 , wherein defining the set of adjustment instructions includes:
defining a set of movement and speed adjustment instructions for moving the fixture with the part positioned on the mold; wherein the instructions adjust the speed of movement of the part relative to the laser beam based on the determined part material thickness estimates such that the ratio of the laser energy applied to the part and the part material thickness is maintained within the predetermined acceptable range.

13 . The method of claim 12 , wherein defining the set of movement and speed adjustment instructions includes defining movement and speed of the fixture in five axes in relation to an orientation of the laser generating component.

14 . The method of claim 9 , wherein the mold is in the shape of a set of teeth of a jaw of a patient to be treated with the dental aligner appliance.

15 . A laser cutting system, comprising:
a laser generating component for producing a laser beam; a fixture for holding a part to be cut by the laser beam; an optical component for focusing the laser beam to create a predetermined range of energy at a cut path to cut through the part while obtaining at least one of a desired edge condition or an edge characteristic; and a controller for adjusting a laser energy applied to a part material thickness by adjusting at least one of the laser generating component, the optical component, and the fixture via at least one control mechanism, wherein the controller receives data regarding the part material thickness, at multiple points along the cut path, and adjusts a ratio of the laser energy applied to the part and the part material thickness to maintain the ratio within a predetermined acceptable range at each point along the cut path; a gas dispensing nozzle oriented at an angle relative to the direction of the laser to blow gas at a point at which the laser contacts the part to blow debris of the part from the cut path; and a suction mechanism located proximate to the point at which the laser contacts the part to remove debris of the part.

16 . The system of claim 15 , wherein the laser energy cuts through the part and into an outer surface of a support for the part, but does not cut through the support.

17 . The system of claim 15 , wherein the controller for adjusting the laser energy provides a mechanism for adjusting at least one of laser generating component power, laser generating component movement, optical component type, optical component movement, fixture movement, gas type, gas pressure, gas temperature, and suction such that a ratio of a laser energy applied to the part and a part material thickness is maintained within a predetermined acceptable range.

18 . The system of claim 15 , wherein the laser energy applied to the part thickness is maintained:
as the part moves at a constant feed rate; by increasing the laser generating comp

Assignees

• Align Technology Inc

Inventors

• Culp James C

Classifications

• A61C13/0006

  Production methods · CPC title

• A61C7/08 Primary

  Mouthpiece-type retainers {or positioners, e.g. for both the lower and upper arch (arch-shaped medicament applicators for teeth or gums A61C19/063; mouthguards for protecting the teeth of sportsmen A63B71/085)} · CPC title

• B23K26/064

  by means of optical elements, e.g. lenses, mirrors or prisms · CPC title

• B23K26/142

  for the removal of by-products · CPC title

• B23K26/08

  Devices involving relative movement between laser beam and workpiece · CPC title