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Design Rules for Hybrid Additive Manufacturing Combining Selective Laser Melting and Micromilling
(2021)
We report on a comprehensive study to evaluate fundamental properties of a hybrid
manufacturing approach, combining selective laser melting and high speed milling, and to characterize
typical geometrical features and conclude on a catalogue of design rules. As for any additive
manufacturing approach, the understanding of the machine properties and the process behaviour as
well as such a selection guide is of upmost importance to foster the implementation of new machining
concepts and support design engineers. Geometrical accuracy between digitally designed and
physically realized parts made of maraging steel and dimensional limits are analyzed by stripe line
projection. In particular, we identify design rules for numerous basic geometric elements like walls,
cylinders, angles, inclinations, overhangs, notches, inner and outer radii of spheres, chamfers in build
direction, and holes of different shape, respectively, as being manufactured by the hybrid approach
and compare them to sole selective laser melting. While the cutting tool defines the manufacturability
of, e.g., edges and corners, the milling itself improves the surface roughness to Ra < 2 µm. Thus,
the given advantages of this hybrid process, e.g., space-resolved and custom-designed roughness
and the superior geometrical accuracy are evaluated. Finally, we exemplify the potential of this
particular promising hybrid approach by demonstrating an injection mold with a conformal cooling
for a charge socket for an electro mobile
This study demonstrates and discusses a novel approach for the fabrication and rapid prototyping of monolithic photonic platforms comprising a ridge-type waveguide with integrated sensing structures. First, the bulk injection-molded cyclic olefin copolymer substrates are micromilled in order to define the physical extension of the ridge structure. Cross-sections down to 30 × 30 µm2, exhibiting a mean surface roughness of 300 nm, are achieved with this process. Subsequently, UV radiation is used to modify the ridge structure’s refractive index, which leads to the formation of an optical waveguide. By employing a phase mask, it is possible to equip the photonic platform with a Bragg grating suitable for temperature measurements with a sensitivity of −5.1 pm K-1. Furthermore, an integrated Fabry-Pérot cavity, generated during the micromilling step as well, enables refractive index measurements with sensitivities up to 1154 nm RIU-1.
This contribution demonstrates and discusses electrically tunable polymer planar Bragg gratings based on bulk cyclic olefin copolymers. A lithographic single-writing-step method and femtosecond laser reductive sintering of copper(II) oxide nanoparticles are subsequently employed in order to generate buried photonic structures and copper conducting paths on top of the polymer substrate. This way, the necessary number of process steps for fabricating a planar polymer-based electro-optical device is greatly reduced. The response of a fully electrified grating structure follows temperature changes, induced by the copper conducting path, with sensitivities up to −31 pm K−1. Dilatometric measurements show that the specimen's behavior is correlated to the situationally reduced thermal expansion of the bulk polymer substrate. In consequence, the tuning response of the photonic platform follows a second order polynomial, whereas a direct current of 30 mA, which correlates to a power consumption of 18.3 mW, leads to a local temperature increase and a residual Bragg wavelength shift of 19.6 K and −547 pm, respectively. Moreover, the outstanding flexibility of the proposed fabrication concept is underlined by demonstrating alternative conducting path geometries, whereas one of the additional designs is adapted to control the spectral width of the Bragg grating's reflection peak.
In this study, we report on the integration of microfluidic channels and optical components by focusing femtosecond laser radiation inside transparent cyclic olefin copolymer (COC) bulk material. An internal localized material modification is triggered based on nonlinear absorption of the laser radiation's high intensities inside the focal volume. The size and shape of the three-dimensional internal modification are controlled by using an adaptive beam shaping setup. The irradiated areas show a positive refractive index shift and can be used as Type I internal optical waveguides. Furthermore, precise control of the spatial pulse-to-pulse distance in combination with a suitable beam profile enables the integration of functional photonic elements, e.g., Bragg gratings, into the waveguide. Thus, it also enables the generation of integrated photonic sensors. In addition, internal fs laser-induced modifications are characterized by a lower thermal stability as compared to the pristine polymer material. By performing a post-annealing process step, internal hollow microstructures are created by gaseous degradation of the exposed areas. Circular microchannels can be generated in a deliberately chosen layout by employing motorized 3D stages. In comparison to etching-based fabrication methods the proposed technology facilitates unlimited channel lengths, as it omits restrictions arising from an etching selectivity and duration. Altogether, this contribution paves the way towards the fabrication of internal three-dimensional optofluidic devices, equipped with a photonic sensor. In contrast, microfluidic and photonic structures are both created by femtosecond laser direct writing inside of transparent polymers.
We report on the effect of different transversal beam shapes on the efficiency of ablation processes and the resulting surface characteristics. A possibility to efficiently apply ultrashort pulsed lasers with high average power is beam shaping. By using a cooled reflective based liquid crystal spatial light modulator to generate different spot distributions, it is possible to spatially allocate the available power to avoid excessive high fluences. In our experiments, we determine the optimal fluence to ablate the maximum volume per watt to be in the range of 0.2-0.4 J/cm². Based on this fluence, we increase the number of spots from one to a maximum of twenty to ablate steel in a multilayer scanning-based process. In this context, we examine the influence of different separation distances between the spots on the ablation efficiency and roughness. Subsequently to these investigations, we develop an efficient roughing process with higher ablation rates and a nearly constant roughness.
This cover image outlines the fabrication method of a polymer planar Bragg grating electrified via femtosecond laser reductive sintering of CuO nanoparticles (see article number 2002203 by Stefan Kefer and co-workers). Based on this sophisticated methodology, bulk cyclic olefin copolymer substrates can be equipped with integrated photonic structures comprising a waveguide as well as a Bragg grating. Its reflective characteristics can be efficiently tuned by means of the subsequently generated Cu conducting path, whereas the applied femtosecond laser process enables an almost limitless degree of freedom towards conducting path geometries.
We report on an optical setup for multi Bessel beam processing combining a refractive axicon and a spatial light modulator.
Based on their particular beam profile, Bessel beams exhibit various advantages over conventional Gaussian beams for
ultrashort pulsed laser processing. Especially for micromachining of transparent materials, applications such as micro-hole
drilling or the generation of voids benefit from the increased focal length of the applied Bessel beam. In addition, on
account of the significantly increased average output power of industrial ultrashort pulsed lasers over the last years, there
is a high demand on multi spot applications for using the available laser power in efficient production processes. Our
optical concept combines the dynamic possibilities of beam splitting using spatial light modulator with the benefits of
Bessel beams facilitating multi Bessel beam processing.
This study demonstrates mobile load monitoring of a composite bicycle component using an application-
customized polymer planar Bragg grating sensor, evaluated by a mobile interrogation unit. After a referencing procedure, the mechanical load of a seat post is monitored while cycling through a test track.
Laser turning with ultra-short laser pulses provides the possibility of manufacturing rotationally symmetric geometries, even of hard to machine materials as fused silica, down to a micrometer scale. In this laser micro machining approach, the laser beam is oriented perpendicularly to the rotational axis and tangentially to the material, whereas the target geometry is realized by moving the constantly rotating specimen according to the specified geometry under the focused laser spot. Due to the fric-tion-less laser ablation it is possible to realize a turning process in fused silica without the use of a contacting tool and therefore without causing mechanical tensions in the work piece. The processing head focuses the laser to a calculated spot size of 18 μm in diameter and the applied processing gas pressure assists in removing the ablated material. In this study, femto-second laser turning of fused silica with a diameter of 3.7 mm is investigated. The influence of the applied pulse energy is stated and the use of a trepanning optic during the turning process is characterized. Furthermore, compre-hensive parameter studies in order to optimize roughness and to find the maximum achievable abla-tion rate are shown. Limited by the mechanical speed of the rotational axis, the highest feasible abla-tion rate is 19.5 mm³/min. A roughness of Ra 0.65 μm are demonstrated.