Optical fiber modules for additive manufacturing systems

An additive manufacturing system comprising:

• a plurality of laser energy sources;
• an optics assembly configured to direct laser energy from the plurality of laser energy sources onto a build surface to form at least one laser energy spot on the build surface;
• a plurality of optical fibers configured to optically couple the plurality of laser energy sources with the optics assembly;
• and
• at least one stray light baffle optically coupled to at least one optical fiber of the plurality of optical fibers, the at least one optical fiber coupled to at least one laser energy source of the plurality of laser energy sources, the at least one stray light baffle disposed between a distal end and a proximal end of the at least one optical fiber, the at least one stray light baffle comprising at least one tapered surface configured to redirect at least a portion of stray laser energy directed toward the at least one laser energy source.

A method for additive manufacturing, comprising:

• transmitting laser energy from at least one laser energy source of a plurality of laser energy sources along a longitudinal direction of at least one optical fiber of a plurality of optical fibers;
• redirecting at least a portion of stray laser energy directed toward the plurality of laser energy sources with at least one tapered surface of at least one stray light baffle, the at least one stray light baffle optically coupled to the at least one optical fiber, the at least one stray light baffle disposed along a length of the at least one optical fiber between a distal end and a proximal end of the at least one optical fiber;
• and
• directing laser energy output from a distal portion of the at least one optical fiber onto a build surface to form at least one laser energy spot on the build surface.