Additive Manufacturing System Using Homogenizers and Shaped Amplifiers
A method of additive manufacture utilizing a uniform laser beam is disclosed. A seed laser projects a laser beam having a first laser beam shape. At least one pre-amplifier is positioned to receive the laser beam and amplify laser beam power. A homogenizer is positioned to receive the amplified laser beam from the at least one pre-amplifier and alter the first laser beam shape into a second laser beam shape. A main amplifier is positioned to receive the amplified laser beam having the second laser beam shape from the homogenizer and amplify laser beam power.
1 . A system for providing a uniform laser beam, the system comprising:
a seed laser projecting a laser beam having a first laser beam shape;
at least one pre-amplifier positioned to receive the laser beam and amplify laser beam power to output an amplified laser beam;
a homogenizer positioned to receive the amplified laser beam from the at least one pre-amplifier and alter the first laser beam shape into a second laser beam shape; and
a main amplifier positioned to receive the amplified laser beam having the second laser beam shape from the homogenizer and further amplify laser beam power to output a further amplified laser beam.
2 . The system of claim 1 , wherein the further amplified laser beam from the main amplifier is directed toward a target in a two-dimensional additive manufacturing system.
3 . The system of claim 1 , further comprising a patterning device positioned between the homogenizer and the main amplifier.
4 . The system of claim 1 , wherein the main amplifier is a slab amplifier.
5 . The system of claim 1 , wherein the main amplifier is a non-cylindrical shaped rod.
6 . The system of claim 1 , wherein the main amplifier has interface plate adapting a non-cylindrical shaped rod to a standard o-ring interface.
7 . A system for providing a uniform laser beam, the system comprising:
a pre-amplifier a positioned to receive the laser beam and amplify laser beam power to output an amplified laser beam;
a non-cylindrical homogenizer positioned to receive the amplified laser beam from the pre-amplifier and alter the first laser beam shape into a second laser beam shape; and
a main amplifier having a non-cylindrical cross section that is positioned to receive the amplified laser beam having the second laser beam shape from the homogenizer and amplify laser beam power to output a further amplified laser beam.
8 . The system of claim 7 , wherein the further amplified laser beam from the main amplifier is directed toward a target in a two-dimensional additive manufacturing system.
9 . The system of claim 7 , further comprising a patterning device positioned between the homogenizer and the main amplifier.
10 . The system of claim 7 , wherein the main amplifier has a square shaped cross section.
11 . The system of claim 7 , wherein the main amplifier is a non-cylindrical shaped rod attached to cylindrical end caps.
12 . The system of claim 7 , wherein the main amplifier has interface plate adapting a non-cylindrical shaped rod to a standard o-ring interface.
13 . A laser amplifier system comprising:
a main amplifier rod having a non-cylindrical cross section; and
an interface plate surrounding and in contact with the main amplifier rod to create a cylindrical o-ring interface.
14 . The system of claim 13 , wherein an amplified laser beam from the main amplifier is directable toward a target in a two-dimensional additive manufacturing system.
15 . The system of claim 13 , further comprising a pre-amplifier a positioned to receive a laser beam and amplify laser beam power to output an amplified laser beam; and
a non-cylindrical homogenizer positioned to receive the amplified laser beam from the pre-amplifier and alter the first laser beam shape into a second laser beam shape matching the non-cylindrical cross section of the main amplifier rod.
16 . The system of claim 13 , wherein the main amplifier has a square shaped cross section.
17 . The system of claim 13 , wherein the main amplifier is a multipass amplifier.
18 . The system of claim 13 , further comprising a patterning device positioned to relay a laser beam toward the main amplifier rod.
19 . The system of claim 13 , wherein the interface plate is attached to the main amplifier with at least one of optical cement, silicone sealant, fluorosilicone sealant, or urethane.
20 . The system of claim 13 , wherein the non-cylindrical cross section of the main amplifier is square shaped.