Laser cutting

Patent metadata

Field	Value
Publication number	US-9403238-B2
Application number	US-201113239173-A
Country	US
Kind code	B2
Filing date	Sep 21, 2011
Priority date	Sep 21, 2011
Publication date	Aug 2, 2016
Grant date	Aug 2, 2016

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

The invention claimed is:

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 from the laser generating component and the support material is capable of mixing in with material associated with the part; and
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 to cut through the part thickness such that the different materials do not mix.

2. The system of claim 1 , wherein the control mechanism includes a fixture control that adjusts a speed of the fixture and 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 adjusts 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.

3. The system of any of claims 1 and 2 , wherein the control mechanism includes a laser power adjustment control that receives data regarding the part material thickness, at multiple points along the cut path where the laser beam will cut the part, and adjusts 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.

4. The system of any of claims 1 and 2 , wherein the control mechanism includes an optics control that adjusts a position of one or more of the number of optical components and 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 adjusts 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.

5. The system of any of claims 1 and 2 , wherein the system includes a gas nozzle directed at a point at which the laser energy contacts the part.

6. The system of claim 5 , wherein the gas nozzle is a gas dispensing nozzle.

7. The system of claim 5 , wherein the system includes a suction mechanism located proximate to where the laser energy contacts the part to remove debris created when the laser energy contacts the part.

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. The system of claim 1 , wherein the speed of the part at the cutting position relative to the laser beam at the cutting position is maintained substantially constant while the part is movable in at least three axes of movement and the power of the laser beam is controlled within a given range based on information about one or more characteristics of at least one of the part material or the mold or a backing material.

10. 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; and
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 part formed thereon, wherein the instructions are executed via a computing device, such that a ratio of a laser energy applied to the part and the 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, and wherein the part is a dental aligner appliance.

11. The method of claim 10 , 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 and 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.

12. The method of claim 11 , 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.

13. The method of claim 10 , 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.

14. The method of claim 10 , wherein creating the specialized mold for creating the specialized part to be positioned on the mold includes creating a virtual project development plan or treatment plan wherein the mold is a representation of a form factor of the mold during the virtual development or treatment plan.

15. The method of claim 14 , wherein the method includes creating a number of specialized molds, each representing a unique part within a respective portion of the virtual project development plan or treatment plan.

16. The method of claim 14 , wherein the method includes creating a virtual mold based on the virtual treatment plan or development plan and wherein the multiple part material thickness estimates for multiple points along the virtual cut path are determined based upon analysis of the virtual mold.

17. The method of claim 14 , wherein the method includes creating multiple virtual molds based on the virtual treatment plan and wherein the multiple part material thickness estimates for multiple points along the virtual cut path are determined for each virtual mold individually based upon analysis of each virtual mold.

18. The method of claim 14 , wherein defining the set of adjustment instructions includes defining a set of movement and speed adjustment instructions for each virtual mold.

19. The method of claim 14 , wherein the method includes creating a number of specialized molds and wherein each specialized mold represents a unique arrangement of teeth along a treatment plan for incrementally moving teeth.

20. The method of claim 19 , wherein the method includes defining multiple cut paths wherein one of the multiple cut paths represents a portion of the part along a gum line of a patient.

21. The method of claim 19 , wherein the method includes defining multiple cut paths wherein one of the multiple cut paths represents a cut on the part that is not along a gum line of a patient.

22. The method of claim 10 , wherein defining a set of adjustment instructions includes instructions for adjusting at least one of the position of the laser generating component, the position of one or more optical components, and the position of the fixture that holds the specialized mold with the part th

Assignees

• Culp James C
• 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

• B23K26/38 Primary

  by boring or cutting · 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