Holographic beam shaping for additive manufacturing

One of the limitations of the process currently is that the intense heat at the focus of the laser, which fuses the metallic powder, leads to thermal stresses and distortion in the part being made. These are difficult to predict or control.

In an EPSRC funded three-year research programme, a team from Cambridge University’s engineering department will use computer-generated holography to control the distribution of the laser’s energy in three dimensions.

Additive manufacturing glass optics

Additive manufacturing: an inconvenient truth

“Rather than using a single beam with a scanning mirror, we can use multiple beams at the same time. We can build up our structure in a more three-dimensional way, which allows us to control things like thermal stresses,” said Tim Wilkinson, professor of photonic engineering and leader of the project.

A key advantage of the holographic approach is the ability to correct for limitations in the system.