Abstract: Systems and methods for additive manufacturing are generally described. In some embodiments, an additive manufacturing system may include an optical sensing system. The optical sensing system may include a housing with an inlet to a chamber configured to receive a laser energy beam emitted from a laser energy source, an optics module, an optical interferometer, and a photosensitive sensor array. In some embodiments, the optical sensing system may include a gas inlet configured to direct a flow of gas from a gas source into the chamber such that a pressure within the chamber is greater than a pressure in an environment surrounding the chamber, thereby pushing contaminants away from the chamber. In some embodiments, the optical sensing system may include one or more transparent debris barriers disposed along an optical path of the laser energy beam.

Abstract: Systems and methods involved in additive manufacturing are disclosed. One or more optical fibers optically couple one or more laser energy sources and an optics assembly. One or more photosensitive detectors are arranged along a length of the one or more optical fibers between an output of the one or more laser energy sources and an input of the optics assembly. Each photosensitive detector among the one or more photosensitive detectors is in a contact-less arrangement with one or more of the two or more optical fibers. Each photosensitive detector among the one or more photosensitive detectors detects fiber fuse-generated propagation of plasma through the one or more optical fibers. The system also includes one or more processors arranged to receive signals from the one or more photosensitive detectors and to control operation of the one or more laser energy sources based at least in part on the signals.

Abstract: Fiber optic laser energy paths including photonic lanterns for use in additive manufacturing systems are disclosed. According to some embodiments, a plurality of photonic lanterns are configured to combine laser energy from a plurality of laser energy sources. According to other embodiments, a first plurality of photonic lanterns may combine laser energy from a plurality of laser energy sources and a second plurality of photonic lanterns may furcate the combined laser energy and direct the furcated laser energy to form a plurality of laser energy pixels on a build surface. Laser energy paths including photonic lanterns my provide enhanced control and redundancy within an additive manufacturing system. The disclosure may apply to laser paths for all types of additive manufacturing systems. Some disclosed embodiments are directed to powder bed fusion additive manufacturing systems including a plurality of laser power sources.

Abstract: Additive manufacturing systems and their methods of use are disclosed. According to some embodiments, a delivery portion of small optical fiber is optically coupled to a large optical fiber by an adiabatic fiber taper. In some instances, an additional reducing taper may be included between the small optical fiber and the adiabatic fiber taper. Increasing the transverse dimension and therefore the cross sectional area of the optical fiber path may reduce the power and/or energy density near the termination of the laser path. Decreased power and/or energy density may provide increased life, reliability, and contamination tolerance of the optic fibers, termination surfaces, and other components located along an optical path connected to a laser energy source.

Abstract: Additive manufacturing systems and related methods directed to load balancing and power optimization for one or more additive manufacturing systems are disclosed. In some embodiments this may include load balancing and power optimization of a plurality of simultaneously running additive manufacturing processes. In some embodiments, one or more additive manufacturing systems may utilize coordinated timing of energy sources, such as laser energy sources, to reduce a maximum combined power during operation of these systems. In other embodiments, the orientations of parts being manufactured may be selected to reduce a maximum energy consumption per layer and/or a variation of energy consumption between layers during additive manufacturing of the parts. The disclosed part orientation and system timing coordination may either be used individually or in combination with one another.

Abstract: Additive manufacturing systems and methods related to the selection and use of groups of laser pixels from an array of laser pixels including a plurality of laser pixels are disclosed. According to some embodiments a plurality of laser pixels may be divided into one or more groups of laser pixels based on one or more process parameters and/or based on the identification of failed laser pixels. The groups may be include fewer laser pixels than the overall array of laser pixels. In some embodiments, an additive manufacturing system may switch between laser pixel groups during a manufacturing process to provide redundancy and/or to enable continued operation of the system even when laser pixel failures occur.

Abstract: An electro-optic beam controller, material processing apparatus, or optical amplifier, and corresponding methods, can include an actively controlled, waveguide-based, optical spatial mode conversion device. The conversion device can include a coupler, which can be a photonic lantern, configured to combine light beams into a common light beam; a sensor configured to measure at least one characteristic of the common light beam; and a controller configured to modulate optical parameters of the individual, respective light beams to set one or more spatial modes of the common light beam. Actively controlled and modulated devices can be used to maintain a stable, diffraction-limited beam for use in an amplification, communications, imaging, laser radar, switching, or laser material processing system. Embodiments can also be used to maintain a fundamental or other spatial mode in an optical fiber even while scaling to kilowatt power.

Abstract: An electro-optic beam controller, material processing apparatus, or optical amplifier, and corresponding methods, can include an actively controlled, waveguide-based, optical spatial mode conversion device. The conversion device can include a coupler, which can be a photonic lantern, configured to combine light beams into a common light beam; a sensor configured to measure at least one characteristic of the common light beam; and a controller configured to modulate optical parameters of the individual, respective light beams to set one or more spatial modes of the common light beam. Actively controlled and modulated devices can be used to maintain a stable, diffraction-limited beam for use in an amplification, communications, imaging, laser radar, switching, or laser material processing system. Embodiments can also be used to maintain a fundamental or other spatial mode in an optical fiber even while scaling to kilowatt power.

Abstract: In various embodiments, wavelength beam combining laser systems incorporate optical fibers and partially reflective output couplers or partially reflective interfaces or surfaces utilized to establish external lasing cavities.

Abstract: In various embodiments, wavelength beam combining laser systems incorporate optical fibers and partially reflective output couplers or partially reflective interfaces or surfaces utilized to establish external lasing cavities.

Abstract: In various embodiments, wavelength beam combining laser systems incorporate optical fibers and partially reflective output couplers or partially reflective interfaces or surfaces utilized to establish external lasing cavities.

Abstract: An electro-optic beam controller, material processing apparatus, or optical amplifier, and corresponding methods, can include an actively controlled, waveguide-based, optical spatial mode conversion device. The conversion device can include a coupler, which can be a photonic lantern, configured to combine light beams into a common light beam; a sensor configured to measure at least one characteristic of the common light beam; and a controller configured to modulate optical parameters of the individual, respective light beams to set one or more spatial modes of the common light beam. Actively controlled and modulated devices can be used to maintain a stable, diffraction-limited beam for use in an amplification, communications, imaging, laser radar, switching, or laser material processing system. Embodiments can also be used to maintain a fundamental or other spatial mode in an optical fiber even while scaling to kilowatt power.

Abstract: In various embodiments, wavelength beam combining laser systems incorporate optical fibers and partially reflective output couplers or partially reflective interfaces or surfaces utilized to establish external lasing cavities.

Abstract: In various embodiments, wavelength beam combining laser systems incorporate optical fibers and partially reflective output couplers or partially reflective interfaces or surfaces utilized to establish external lasing cavities.