The AM-MODULE III is an integrated pre-focusing beam deflection unit specifically for use in additive manufacturing. Thanks to its dust-tight housing and integrated collimating optics, the AM-MODULE III is the ideal deflection unit for use in industrial production.
In additive manufacturing, efficiency of the production line and AM equipment is the key to success. The goal is to keep the costs per part as low as possible and thus remain competitive with existing manufacturing methods. To achieve this, all aspects of the AM machine are trimmed for high exposure speeds and high reliability at the same time. After all, when a machine is down, it doesn’t earn money.
This is precisely what we kept in mind when designing the AM-MODULE III. A dust-proof housing and manufacturing in an ISO Class 7 clean room allows the use of more powerful lasers. In addition, the spot can be adjusted dynamically in diameter using the integrated zoom function without losing image quality. As a result, fine structures are exposed with high resolution and large areas can be filled with an enlarged spot diameter at constant power density and scanning speed. This makes additive manufacturing a real competitor to existing manufacturing methods and it can be used for a wide range of applications.
Combined with the integrated design and the resulting high reliability in the industrial production environment, this increase in performance enables AM users to take the next step: The step from rapid prototyping to additive production!
Highest dynamics
Dynamic Zoom function
Optimized for industrial production
Clean room production
WHAT IS SPECIAL ABOUT THE AM MODULE III?
OPTIMIZED FOR INDUSTRIAL AM PRODUCTION
The AM-MODULE III is designed for additive production. This means reliability and process safety were basic ideas in the development of the system. Precise and pre-aligned integrated collimation and scanner optics allow to use lasers with best beam quality. The additional zoom function ensures that the focus shape is always maintained, even when working with dynamically enlarged spot diameters. And it can also dynamically compensate for possible variations in energy density in the scan field.
The philosophy of production and reliability is reflected in various aspects: for example, the digital scanners allow a convenient read-back of position data, which can then be easily merged with measurement data from the coaxial process light or camera port. This enables precise process monitoring and control. In addition, the housing is also designed for productivity: It enables low-maintenance operation, thanks to its optimized dust-proof housing design and innovative RAYVOLUTION DRIVE technology. And with its scalable design, multiple lasers can work simultaneously on one component, enabling even the shortest production cycle times in demanding production lines.
Precisely this combination makes the AM-MODULE III the optimal solution for your AM production. See for yourself:
FACTS & USE CASES
HIGHER PRODUCTIVITY THROUGH DYNAMIC ZOOM FUNCTION
The right brush size for every application. This is made possible by the highly dynamic zoom function of the AM-MODULE III. One of the challenges in additive manufacturing is to keep the exposure time per plane as short as possible in order to produce profitably. For this reason, the laser is regularly defocused to fill large areas. This allows more area to be filled with each pass, saving the number of hatches and thus processing time.
Comparison of zoom function vs. defocus
However, like a brush that is pressed on too hard, the shape of the laser spots is poorly defined outside the focus position. For special beam profiles such as tophat or ring mode, this becomes particularly obvious, because here the special beam shape is lost even with slight defocusing, and the advantages of a higher exposure speed without balling effects and spattering are lost. Therefore, defocus can only be used to fill areas to a limited extent.
In contrast, the zoom function of the AM-MODULE III allows dynamic adjustment of the focus diameter by up to 2x and at the same time ensures that it is still possible to work in focus with an undisturbed beam profile even with an enlarged spot diameter. This way, the higher exposure speeds of using a ring or tophat profile can be effectively combined with the time savings of a larger spot diameter. And the AM-MODULE III thus makes a decisive contribution to ensuring that the high build rates that are so important for additive production can also be implemented in the machine.
FASTER EXPOSURE SPEED THANKS TO RAYVOLUTION DRIVE
With RAYVOLUTION DRIVE, the z-axis follows the xy-movements of deflection units with quartz mirrors without delay. Quite in contrast to a standard z-axis, which shows significantly slower dynamics. When using highly dynamic silicon carbide mirrors, a small difference in dynamics still remains visible, which can be compensated using the function Tracking Error Compensation of the SP-ICE-3 Control Card.
Pre-focusing beam deflection units such as the AM-MODULE III use a combination of moving and fixed lenses in front of the scan mirrors to focus the laser. To keep the focus in a constant z-plane, the lens is tracked and the focal length adjusted with each movement. But at higher dynamics, many focus shifters can no longer follow the movement of the XY mirrors, which can lead to non-uniform power input in the powder.
To take advantage of a pre-focusing system and at the same time use the full dynamics of the XY deflection unit, the RAYVOLUTION DRIVE (RD) technology was developed. It is based on the moving coil principle to shift the lenses, which allows very fast movements of the lens. This allows to follow the xy deflection unit with almost no delay, while always maintaining a stable z-position of the focus.
In addition, an innovative mount used for the RAYVOLUTION DRIVE allows highly accurate alignment and guiding of the lenses even under dynamic movements and enables excellent imaging performance of the lens system. Even single mode fiber lasers or special beam shaping like Ring mode lasers remain nearly undisturbed. The frictionless guidance also leads to significantly reduced wear and makes the RAYVOLUTION DRIVE technology almost maintenance-free.
With its high dynamics and reliability under production conditions, the RAYVOLUTION DRIVE technology is made for industrial additive production. It ensures optimal flat-field correction even at high scanning speeds throughout the entire up to 900 x 900 mm² processing field. In addition, the RAYVOLUTION DRIVE enables highly dynamic scanning strategies such as hatching with a constant focus position, making the AM-MODULE III the ideal solution for precise and highly dynamic AM applications.
SCANFIELD CALIBRATOR: HIGH-PRECISION CALIBRATION OF MULTI-HEAD SYSTEMS
Calibration of the overlap area of an AM machine made of four AM MODUL III
A precisely calibrated processing field is crucial for the part quality of an AM machine. Poor calibrations lead to measurement inaccuracies, geometric deformations and misalignments that can quickly render the build parts useless, especially in aerospace and medical applications. In addition, accurate and regular calibration ensures reproducibility across different batches, which is important in a serial production. But the calibration of AM machines and especially multi-head systems is complex and time-consuming.
In order to assist the user with this task, the RAYLASE SCAN-FIELDCALIBRATOR was introduced. It fully automatically measures the processing field with typically 49 x49 measuring points and uses them to create optimized correction files for the deflection unit. The SFC offers an average correction accuracy in the process field of ± 15 µm, comparable to a coordinate measuring machine. The complete calibration process is carried out via a user interface with just a few clicks, preventing media discontinuity and thus reducing potential sources of error. As a result, even the regular calibration of multi-head systems in AM production becomes a convenient routine.
RAYSPECTOR: PROCESSOPTIMIZATION WITH PYROMETER & HIGHSPEED CAMERA
„Data is the new gold." It allows process control and optimization, quality control and documentation. Therefore, it is important to collect and use data during the manufacturing process. But for process monitoring to work smoothly, the scanning system and components must be optimally matched. On-axis data in particular can only be meaningfully interpreted if they are merged with the position values of the mirrors afterwards. The AM-MODULE III with its digital electronics offer optimal pre-conditions for this, as for example the position values of the galvos can be read back together with the data of a pyrometer via the SP-ICE-3 card and conveniently combined to form a heat map.
Highspeed camera images of a melting pool with donut and Gaussian caustics
Also for an observation of the laser process with high-speed cameras, the combination of RAYSPECTOR and AM-MODULE III offers the suitable solution. With the RAYVOLUTION DRIVE technology, the imaging optics of the camera in the RAYSPECTOR can be moved highly dynamically and synchronously with the scan mirrors, thus enabling an in focus observation of the laser process. These analyses are particularly interesting for process optimization, as they help the user to recognize the dynamics of the melt pool and possible irregularities and to adjust the process parameters accordingly.
OTHER SUITABLE ACCESSORIES
SP-ICE 3: CONTROL CARD WITH FEEDBACK FUNCTION
The central control unit for runtime-critical process steps. Enables synchronous control of the deflection unit, laser and peripherals and also allows scanner and sensor signals to be read out and connected comfortably.
GOOD REASONS TO CHOOSE RAYLASE
THIS MAKES RAYLASE SPECIAL
Systems view instead of components
Modern production systems for laser processing are usually designed specifically for one process step and are highly optimized. It is therefore important to consider the interplay with the other machine components when selecting suitable beam deflection units. At RAYLASE, we therefore always have the entire solution in mind and offer our customers assistance in putting together suitable components.
Broad application knowledge
For many processes, the beam deflection unit is a decisive component. Often it determines whether the desired spot parameters and processing speeds can be implemented on the component. To identify the optimal solution here, we support our customers in selecting the right beam delivery components and sensor technology. and perform simulations of the laser processes developed by our customers. In addition, we provide support in the parameterization of the laser and deflection unit or software functionality through the experts at our Technical Competence Center TCC.
On-site support for implementation and service
Our customers are the experts for their application - we are the experts for our beam deflection units. That's why we support our customers during the commissioning of our products - if necessary also directly on site. In this way, we at RAYLASE ensure that our system is optimally adjusted and permanently delivers what it is capable of.
Education & training on the system
Modern laser deflection units are complex systems. Therefore, it is important to have a good knowledge of their characteristics. Because only when users know how the various parameters interact the optimum process becomes possible. For this reason, we at RAYLASE put a high priority on training for our products. In addition, we also offer our customers on-site training directly on the system, if required, to enable users to operate the system independently.
The POWER OF WE
Together you achieve more. At RAYLASE, we are convinced about this. That's why we place great value on cooperation in a spirit of partnership and open communication at equal level – from expert to expert. Because only when we jointly find the best solution and successful integrate it into the machine, everyone involved benefits in the end - our customers, us and also the end users.
