US-20260124805-A1 - Solid State Routing of Patterned Light for Additive Manufacturing Optimization

US20260124805A1US 20260124805 A1US20260124805 A1US 20260124805A1US-20260124805-A1

Abstract

A solid state beam routing apparatus includes a controller and a spatial angular light valve arranged to direct a two-dimensional patterned light beam through a predetermined angle in response to an applied voltage. A bed is arranged to receive the two-dimensional patterned light beam as a succession of tiles. In some embodiments, one or more solid state galvo mechanisms are used to direct the two-dimensional patterned light beams formed by the light valve to the multiple powder bed chambers.

Inventors

James A. DEMUTH
Francis L. Leard
Erik Toomre

Assignees

Seurat Technologies, Inc.

Dates

Publication Date: 20260507
Application Date: 20251103

Claims (18)

1 . A method comprising: apply an image pattern at a light valve to an energy beam to generate a first positive patterned beam and a second negative patterned beam according to the applied image pattern; and using a plurality of solid-state beam switching units to remap the second negative patterned beam and to direct both the first positive patterned beam and the remapped second negative patterned beam to at least one of a plurality of powder bed chambers.
2 . The method of claim 1 , wherein at least one of the solid state beam switching units is a spatial angular light valve arranged to direct one of the first positive patterned beam and the second negative patterned beam through a predetermined angle in response to an applied optical address pattern and a stimuli selected to be at least one of voltage, current, heat, sound, light, electric field, magnetic field, chemical reaction, quantum spin change, energy, or mechanical force.
3 . The method of claim 1 , wherein at least one of the plurality of solid-state beam switching units modifies a pattern of one of the first positive patterned beam and the second negative patterned beam.
4 . The method of claim 1 , wherein at least one of light pattern intensity, light pattern orientation, and light pattern size is transformed.
5 . The method of claim 1 , wherein the first positive patterned beam and second negative patterned beam are at least in part combined.
6 . The method of claim 1 , wherein at least some of the plurality of solid-state beam switching units are arranged in a switching hierarchy.
7 . The method of claim 1 , wherein at least some of the plurality of solid-state beam switching units are arranged in a binary tree switching hierarchy.
8 . The method of claim 1 , wherein the first positive patterned beam and the second negative patterned beam generated at the light valve preserve both the spatial and angular power density content when passed through at least one solid state beam switching unit and received at a powder bed.
9 . The method of claim 1 , wherein the energy beam comprises an unpatterned power beam, a patterned write beam, and a recycled energy based on the second negative patterned beam.
10 . A solid-state switchyard light recycling system, comprising: a light valve configured to apply an image pattern to an energy beam to generate a first positive patterned beam and a second negative patterned beam according to the applied image pattern; and a plurality of solid-state beam switching units configured to remap the second negative patterned beam and to direct both the first positive patterned beam and the remapped second negative patterned beam to at least one of a plurality of powder bed chambers.
11 . The solid-state switchyard light recycling system of claim 10 , wherein at least one of the solid state beam switching units is a spatial angular light valve arranged to direct one of the first positive patterned beam and the second negative patterned beam through a predetermined angle in response to an applied optical address pattern and a stimuli selected to be at least one of voltage, current, heat, sound, light, electric field, magnetic field, chemical reaction, quantum spin change, energy, or mechanical force.
12 . The solid-state switchyard light recycling system of claim 10 , wherein at least one of the plurality of solid-state beam switching units modifies a pattern of one of the first positive patterned beam and the second negative patterned beam.
13 . The solid-state switchyard light recycling system of claim 10 , wherein at least one of light pattern intensity, light pattern orientation, and light pattern size is transformed.
14 . The solid-state switchyard light recycling system of claim 10 , wherein the first positive patterned beam and second negative patterned beam are at least in part combined.
15 . The solid-state switchyard light recycling system of claim 10 , wherein at least some of the plurality of solid-state beam switching units are arranged in a switching hierarchy.
16 . The solid-state switchyard light recycling system of claim 10 , wherein at least some of the plurality of solid-state beam switching units are arranged in a binary tree switching hierarchy.
17 . The solid-state switchyard light recycling system of claim 10 , wherein the first positive patterned beam and the second negative patterned beam generated at the light valve preserve both the spatial and angular power density content when passed through at least one solid state beam switching unit and received at a powder bed.
18 . The solid-state switchyard light recycling system of claim 10 , wherein the energy beam comprises an unpatterned power beam, a patterned write beam, and a recycled energy based on the second negative patterned beam.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATION This application is a continuation of U.S. patent application Ser. No. 15/977,476, filed May 11, 2018, which claims the priority benefit of U.S. Patent Application No. 62/504,853, filed on May 11, 2017, both of which are hereby incorporated by reference in their entirety. TECHNICAL FIELD The present disclosure generally relates to optics for additive manufacturing and, more specifically, to an optical system including solid state routing subsystems optionally able to recycle patterned light. BACKGROUND Laser based systems for additive manufacturing typically require costly and difficult to control optomechanical systems for routing light between a light source and a powder bed. Such optomechanical systems require precise calibration, and are susceptible to damage or misalignment due to vibration or movement in an industrial or factory setting. Reducing or eliminating such optomechanical systems will advantageously reduce system cost. Another substantial system cost relates to energy usage. If light is patterned by masks or optical light valves, light not used in the pattern is often discarded, decreasing overall system energy efficiency. For example, a laser-based additive manufacturing system can involve creating a pattern by splitting a light source into negative and positive images, with one image used to build parts and the other discarded. Such patterns can be created by use of a liquid crystal based light valve that allows for the spatial modulation of transmitted or reflected light by rotating the electromagnetic wave polarization state. A typical example would have polarized light “drive beam” passing through a liquid crystal filled light valve, which then spatially imprints a pattern in polarization space on the drive beam. The polarization state of the light desired is allowed to continue to the rest of the optical system, and the unwanted state is rejected and thrown away to a beam dump or other energy rejection device. BRIEF DESCRIPTION OF THE DRAWINGS Non-limiting and non-exhaustive embodiments of the present disclosure are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various figures unless otherwise specified. FIG. 1A illustrates an additive manufacturing system; FIG. 1B is a top view of a structure being formed on an additive manufacturing system; FIG. 2 illustrates an additive manufacturing method; FIG. 3A is a cartoon illustrating an additive manufacturing system including lasers; FIG. 3B is a detailed description of the light patterning unit shown in FIG. 3A; FIG. 3C is one embodiment of an additive manufacturing system with a “switchyard” for directing and repatterning light using multiple image relays; FIG. 3D illustrates a switchyard system supporting reuse of patterned two-dimensional energy; FIG. 3E illustrates a mirror image pixel remapping; FIG. 3F illustrates a series of image transforming image relays for pixel remapping; FIG. 4A is a diagram of a layout of an energy patterning binary tree system for laser light recycling in an additive manufacturing process in accordance with an embodiment of the present disclosure; FIG. 4B is a diagram of illustrating pattern recycling from one input to multiple outputs; FIG. 4C is a diagram of illustrating pattern recycling from multiple inputs to one output; FIG. 4D is a schematic example of an implementation of the switchyard concept supporting two light valve patterning steps and beam re-direction where switching is available for at least some energy steering units; FIG. 4E is a schematic example of an implementation of the switchyard concept supporting two light valve patterning steps and beam re-direction where switching is available for all energy steering units; FIG. 5A is a cartoon illustrating area printing of multiple tiles using a solid-state system with a print bar; FIG. 5B is a cartoon illustrating area printing of multiple tiles using a solid-state system with a matrix sized to be coextensive with a powder bed; and FIG. 5C is a cartoon illustrating area printing of multiple tiles using a solid-state system with a matrix having individual steering units and sized to be coextensive with a powder bed; FIG. 6A is a cartoon illustrating a solid-state scanner; FIG. 6B is a cartoon illustrating a solid-state scanner with an applied voltage acting to steer a light pattern; FIG. 6C is a cartoon illustrating a solid-state scanner with multiple discrete zones, each acting under an applied voltage acting to steer a light in a different direction; FIG. 6D is a cartoon illustrating a solid-state scanner with multiple discrete zones, each acting under an arbitrary applied voltage acting to repattern an incoming light pattern; FIG. 6E is a cartoon illustrating a solid-state scanner having five time sequenced and different voltage variations that result in an entire beam being delivered to five different angles; FIG. 6F is a carto