Laser beam profiling system for use in laser powder bed fusion manufacturing

A portable testing apparatus for use with a laser powder bed fusion additive manufacturing device, wherein the additive manufacturing device includes a laser for generating a non-stationary laser beam and a build plane positioned at a predetermined location relative to the non-stationary laser beam, and wherein the portable testing apparatus includes:

• (a) a support having an upper surface, wherein the upper surface is adapted to receive and absorb laser light generated by the non-stationary laser beam;
• (b) a plurality of pin-hole defining structures mounted at predetermined locations in the support such that each pin-hole is positioned to receive the laser light generated by the non-stationary laser beam, and such that each pin-hole is elevated at a predetermined height above the upper surface of the support and parallel thereto;
• (c) a fiber optic cable disposed within each pin-hole defining structure, wherein each fiber optic cable has a proximal end at which the laser light is received through the pin-hole and a distal end to which the laser light is delivered;
• (d) a photodetector located at the distal end of each fiber optic cable, wherein the photodetector converts the laser light delivered to the photodetector into electrical voltage output signals that are based on intensity of the laser light received through each pin-hole;
• (e) a data acquisition device in communication with the photodetector, wherein the data acquisition device receives, saves, organizes, and analyzes the electrical signals as a function of time, or time and position, relative to the pin-holes through which the laser light was received;
• and
• (f) a data analysis algorithm associated with the data acquisition device that calculates and determines laser beam quality based on data acquired from multiple passes of the non-stationary laser beam over the plurality of pin-holes.

A system for characterizing the beam of a laser used in a laser powder bed fusion additive manufacturing device, comprising:

• (a) a laser powder bed fusion additive manufacturing device, wherein the laser powder bed fusion additive manufacturing device includes:
• (i) at least one laser, wherein the laser generates a non-stationary laser beam having known or predetermined characteristics;
• and
• (ii) a build plane positioned at a predetermined location relative to the non-stationary laser beam,
• (iii) wherein the non-stationary laser beam translates across the build plane in a controlled manner during additive manufacturing processes;
• (b) a portable testing apparatus, wherein the portable testing apparatus is adapted to be placed within the laser powder bed fusion additive manufacturing device, and wherein the portable testing apparatus includes:
• (i) a support having an upper surface adapted to receive and absorb laser light generated by the non-stationary laser beam;
• (ii) a plurality of pin-hole defining structures each positioned to receive the laser light generated by the non-stationary laser beam, and such that each pin-hole is elevated at a predetermined height above the upper surface of the support and parallel thereto;
• (iii) a fiber optic cable disposed within each pin-hole defining structure, wherein each fiber optic cable has a proximal end at which the laser light is received through the pin-hole and a distal end to which the laser light is delivered;
• and
• (iv) a photodetector located at the distal end of each fiber optic cable, wherein the photodetector converts the laser light delivered to the photodetector into electrical voltage output signals that are based on intensity of the laser light received through each pin-hole;
• (c) a data acquisition device in communication with the photodetector, wherein the data acquisition device receives, saves, organizes, and analyzes the electrical signals as a function of time, or time and position, relative to the pin-holes through which the laser light was received;
• and
• (d) a data analysis algorithm associated with the data acquisition device that calculates and determines laser beam quality based on data acquired from multiple passes of the non-stationary laser beam over the plurality of pin-holes.