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<p>Additive manufacturing technologies offer great potential for a higher material usage and more design flexibility. Currently these technologies, e.g., powder bed fusion with laser beam (PBF-LB), are mostly used for prototyping and small-scale manufacturing because of their comparably low productivity. To increase productivity, different approaches of beam shaping and splitting are currently the focus of research. The use of beam splitters in scanner systems for additive manufacturing with PBF-LB promises higher possible productivity and a multiplication of the achievable build rate. But this change in the optic system leads to mirror angle-dependent optical errors on the build plate level, e.g., spot distance error, spot rotation, and focus diameter deviation. To achieve a build quality comparable to a process without beam splitters, a compensation of the optical errors on the build plate is necessary. In this paper, a vector-based model for the simulation of optical errors based on their changes in travel length to the build plate is presented and compared with experimental results. The experimental results for the spot distance error have a difference to the simulated results of less than 15% of the maximal experimental spot distance error. In addition, the resulting errors for two beam splitter positions are compared concerning the achievable minimal errors. This highlights that a partial compensation is feasible for the spot distance error.</p>

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Model for optical errors using a beam splitter with high separation angle in powder bed fusion

  • 期刊论文

  • 发表日期：

    2025年4月1日

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  • Florian Joachim Oskar Spieth,
  • Thorsten Heeling,
  • Hans-Christian Möhring

摘要

Additive manufacturing technologies offer great potential for a higher material usage and more design flexibility. Currently these technologies, e.g., powder bed fusion with laser beam (PBF-LB), are mostly used for prototyping and small-scale manufacturing because of their comparably low productivity. To increase productivity, different approaches of beam shaping and splitting are currently the focus of research. The use of beam splitters in scanner systems for additive manufacturing with PBF-LB promises higher possible productivity and a multiplication of the achievable build rate. But this change in the optic system leads to mirror angle-dependent optical errors on the build plate level, e.g., spot distance error, spot rotation, and focus diameter deviation. To achieve a build quality comparable to a process without beam splitters, a compensation of the optical errors on the build plate is necessary. In this paper, a vector-based model for the simulation of optical errors based on their changes in travel length to the build plate is presented and compared with experimental results. The experimental results for the spot distance error have a difference to the simulated results of less than 15% of the maximal experimental spot distance error. In addition, the resulting errors for two beam splitter positions are compared concerning the achievable minimal errors. This highlights that a partial compensation is feasible for the spot distance error.