Scan field and work plane evaluation and orientation for high-speed laser motion systems
System and methods for evaluating build platform flatness and parallelism relative to a focal plane of a high-speed laser in high-speed laser motion systems, wherein the high-speed laser motion systems include the high-speed laser that generates a laser beam, and the build platform having a work plane, comprising positioning a plurality of pin-hole sensors within the focal plane of the high-speed laser, wherein each of the pin-hole sensors is positioned at a predetermined location; directing the laser beam to the predetermined locations of each pin-hole sensor; measuring a spot size of the laser beam at each pin-hole sensor, wherein the spot size at each pin-hole defining structure has a measureable diameter; comparing the measurable diameters obtained at each pin-hole sensor; and adjusting the work plane of the build platform to a position where the measurable diameters of the spot sizes are equal at each pin-hole sensor.
1 . A method for evaluating build platform flatness and parallelism relative to a focal plane of a high-speed laser in high-speed laser motion systems, wherein the high-speed laser motion systems include the high-speed laser that generates a laser beam, and the build platform having a work plane, comprising:
(a) positioning a plurality of pin-hole sensors within the focal plane of the high-speed laser, wherein each of the pin-hole sensors is positioned at a predetermined location;
(b) directing the laser beam to the predetermined locations of each pin-hole sensor;
(c) measuring a spot size of the laser beam at each pin-hole sensor, wherein the spot size at each pin-hole defining structure has a measurable diameter;
(d) comparing the measurable diameters obtained at each pin-hole sensor; and
(e) adjusting the work plane of the build platform to a position where the measurable diameters of the spot sizes are equal at each pin-hole sensor.
2 . The method of claim 1 , wherein the focal plane of the high-speed laser is ideally parallel to the work plane of the build platform.
3 . The method of claim 1 , further comprising repeatedly redirecting the laser beam to the predetermined locations of each pin-hole sensor, re-measuring the spot size of the laser beam at each pin-hole sensor, and re-adjusting the work plane of the build platform.
4 . The method of claim 1 , further comprising providing feedback to an operator indicating the adjustments necessary for making the work plane of the build platform parallel with the focal plane of the high-speed laser.
5 . The method of claim 1 , further comprising analyzing working parameters of the high-speed laser motion systems, by:
(a) measuring the spot size of the laser beam at each pin-hole sensor;
(b) comparing the measured spot sizes obtained at each pin-hole sensor;
(c) calculating changes in the working parameters due to non-uniformity between the measured spot sizes; and
(d) recording the location and profile of the work plane for use during processing.
6 . The method of claim 5 , further comprising providing feedback to an operator indicating the adjustments necessary for making the work plane of the build platform parallel with the focal plane of the high-speed laser.
7 . The method of claim 5 , wherein the high-speed laser motion systems are two-dimensional.
8 . The method of claim 1 , further comprising analyzing orientation of the high-speed laser motion systems, by:
(a) measuring the spot size of the laser beam at each pin-hole sensor;
(b) comparing the measured spot sizes obtained at each pin-hole sensor;
(c) calculating necessary movement of the high-speed laser in the z-axis due to non-uniformity between the measured spot sizes;
(d) recording the location and profile of the work plane for use during processing;
(e) running a measurement cycle with z-axis compensation; and
(f) verifying uniformity in the measured spot sizes between each pin-hole sensor.
9 . The method of claim 8 , further comprising providing feedback to an operator indicating the adjustments necessary for making the work plane of the build platform parallel with the focal plane of the high-speed laser.
10 . The method of claim 8 , wherein the high-speed laser motion systems are three-dimensional.