Systems and methods for laser processing using a modified laser beam having a non-Gaussian energy distribution are described herein In some embodiments, a laser processing system includes a laser source that outputs a laser beam having a Gaussian energy distribution, and a beam modifier positioned in a path of the output beam. The beam modifier controllably modifies the Gaussian energy distribution of the output laser beam along at least one axis perpendicular to the beam's axis of travel. In various embodiments, the laser processing system includes a beam delivery sub-subsystem that operates in a raster mode. In such embodiments, the subsystem can raster the modified beam across a material to form raster lines for transferring an image or pattern to the material.

This invention concerns a module for insertion into an additive manufacturing apparatus. The module comprising a frame mountable in a fixed position in the additive manufacturing apparatus, the frame defining a build chamber and a dosing chamber. A build platform is movable in the build chamber for supporting a powder bed during additive manufacturing of a part. A dosing piston is movable in the dosing chamber to push powder from the dosing chamber. A mechanism mechanically links the build platform to the dosing piston such that downward movement of the build platform in the build chamber results in upward movement of the dosing piston in the dosing chamber.

The present disclosure provides three-dimensional (3D) printing methods, apparatuses, and systems using, inter alia, a controller that regulates formation of at least one 3D object (e.g., in real time during the 3D printing); and a non-transitory computer-readable medium facilitating the same. For example, a controller that regulates a deformation of at least a portion of the 3D object. The control may be in situ control. The control may be real-time control during the 3D printing process. For example, the control may be during a physical-attribute pulse. The present disclosure provides various methods, apparatuses, systems and software for estimating the fundamental length scale of a melt pool, and for various tools that increase the accuracy of the 3D printing.

The thermal processing device includes a stage, a continuous wave electromagnetic radiation source, a series of lenses, a translation mechanism, a detection module, a three-dimensional auto-focus, and a computer system. The stage is configured to receive a substrate thereon. The continuous wave electromagnetic radiation source is disposed adjacent the stage, and is configured to emit continuous wave electromagnetic radiation along a path towards the substrate. The series of lenses is disposed between the continuous wave electromagnetic radiation source and the stage, and are configured to condense the continuous wave electromagnetic radiation into a line of continuous wave electromagnetic radiation on a surface of the substrate. The translation mechanism is configured to translate the stage and the line of continuous wave electromagnetic radiation relative to one another. The detection module is positioned within the path, and is configured to detect continuous wave electromagnetic radiation.

A laser apparatus includes a plurality of laser modules each generating a laser line in a working plane. The laser modules are juxtaposed so that the laser lines generated by the modules combine into a single laser line. Each of the laser modules includes at least one laser line generator. The laser line generator includes two linear arrays of strips of laser diodes each emitting a focused laser beam. The two linear arrays are arranged parallel to each other so that the strips are staggered. The two sets of parallel laser beams generated by the two linear arrays of strips, respectively, are merged into a single laser line by a set of mirrors. The linear arrays of strips of laser diodes and the mirrors are arranged so that the two sets of laser beams trace optical paths of the same length before being merged into a single laser line.

A method, apparatus, and system are provided to monitor and characterize the dynamics of a phase change region (PCR) created during laser welding, specifically keyhole welding, and other material modification processes, using low-coherence interferometry. By directing a measurement beam to multiple locations within and overlapping with the PCR, the system, apparatus, and method are used to determine, in real time, spatial and temporal characteristics of the weld such as keyhole depth, length, width, shape and whether the keyhole is unstable, closes or collapses. This information is important in determining the quality and material properties of a completed finished weld. It can also be used with feedback to modify the material modification process in real time.

A welding method for joining workpieces (10) made of hot-crack-sensitive materials at a lap joint by means of a remote laser welding device. A stitched weld seam (11) with the equivalent strength of a continuous weld seam (11) is produced from a plurality of weld seam sections (13). The power input of the laser beam (21) changes periodically between a minimum and a maximum value while the laser spot (22) describes an anharmonically oscillating pendulum motion on the workpiece surface plane (18). The welding and the formation of the weld seam sections (13) take place in the phases of the power input with the maximum value. The anharmonically oscillating pendulum motion takes place with an oscillation frequency of 2 to 25 Hz and an amplitude in the range of 1 to 20 mm. The method is intended for welding of hot-crack-sensitive aluminum materials, e.g. for production of automobile bodies.

A device and a method for beam shaping and beam movement during laser material processing with a laser beam source (1) for continuously emitting a laser beam (2), a first optical deflection element (3), a second optical deflection element (4), and an optical focusing element (5) arranged between the second optical deflection element (4) and a workpiece surface (7) to be processed. The second optical deflection element (4) is configured to displace a point of incidence of the laser beam (2) on the workpiece surface (7), and the first optical deflection element (3) is configured to alter a position of a focal plane of the laser beam (2) relative to the workpiece surface (7) by means of a translational movement and/or to change an intensity distribution within a beam cross section of the laser beam.

A machining apparatus for laser machining a workpiece in a machining zone is provided, having an interface for a machining laser source for generating a machining laser beam with a direction of propagation; an outlet opening for the machining laser beam; and an optical system between the interface and the outlet opening, wherein the optical system has: at least one optical unit that adjusts the focal length of the optical system, and at least one stationary laser beam guiding device with at least one movable surface, wherein the at least one movable surface can be adjusted such that it modifies the focal length of the optical system and/or the beam parameter product of the machining laser beam integrated over time in at least one operating mode. Further provided is a method for laser machining a workpiece.

A method and device for laser cladding by independently heating the cladding material and the surface of the workpiece consist in formation of the series of parallel annular laser beams, possibly different wavelengths, with an adjustable distribution of laser radiation power across the annular beams. The annular beams are transformed into a series of conical beams which are separately focused along a single optical axis, along which the cladding material is fed. The device can be supplemented with a cylindrical mirror for the multipass laser radiation through the stream of cladding material with the possibility of the laser radiation return to the laser resonator.