# US 2023/0056367 A1 · Optical fibers including endcaps for use in additive manufacturing > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2023/0056367 A1 - Document ID: US20230056367A1 - Status: Published application - Kind: A1 - Application number: 17/868,883 - Filed: 2022-07-20 - Published: 2023-02-23 - Earliest claimed: 2021-08-19 - Assignees: VulcanForms Inc. - Applicants: VulcanForms Inc. - Inventors: Manuel Joseph Leonardo; Martin C. Feldmann - Web page: https://patentgrep.com/patent/US20230056367A1 ## CPC - B29C 64/268: using laser beams; using electron beams [EB] - B29C 64/277: using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] - B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - G02B 6/262: {Optical details of coupling light into, or out of, or between fibre ends, e.g. special fibre end shapes or associated optical elements} - G02B 6/32: having lens focusing means {positioned between opposed fibre ends (with lens being an integral part of the single fibre end G02B6/262)} - G02B 6/3636: {the mechanical coupling means being grooves (G02B6/3652 takes precedence)} - G02B 6/3676: {Stacked arrangement} - Y02P 10/25: Process efficiency - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract Systems and methods for additive manufacturing are generally described. According to certain aspects, endcaps optically coupled to optical fibers of additive manufacturing systems are provided. In some aspects, methods for reducing a power area density of laser energy within an endcap are provided. The endcaps described herein may be used to at least partially mitigate thermal cycling that may result from the transmission of laser energy through interfaces of an additive manufacturing system. ## Claims ### Claim 1 An additive manufacturing system comprising: a laser energy source; an optics assembly configured to direct laser energy from the laser energy source onto a build surface to form a laser energy spot on the build surface; an optical fiber optically coupled with the laser energy source; and an endcap disposed on and optically coupled with a distal end of the optical fiber, wherein a surface area of a distal surface of the endcap is larger than a transverse cross sectional area of the distal end of the optical fiber, and wherein the endcap is optically coupled with the optics assembly. ### Claim 2 (depends on 1) The additive manufacturing system of claim 1, wherein the endcap is configured to increase a transmission area of laser energy transmitted from the laser energy source to reduce a power area density of the transmitted laser energy. ### Claim 3 An additive manufacturing system comprising: a laser energy source; an optics assembly configured to direct laser energy from the laser energy source onto a build surface to form a laser energy spot on the build surface; an optical fiber optically coupled with the laser energy source; and an endcap disposed on and optically coupled with a distal end of the optical fiber, wherein the endcap is configured to increase a transmission area of laser energy transmitted from the laser energy source to reduce a power area density of the transmitted laser energy. ### Claim 4 (depends on 3) The additive manufacturing system of claim 3, wherein a surface area of a distal surface of the endcap is larger than a transverse cross-sectional area of the distal end of the optical fiber. ### Claim 5 A method for additive manufacturing, comprising: transmitting laser energy from a laser energy source along an axial dimension of an optical fiber; reducing a power area density of the transmitted laser energy by increasing a transmission area of the transmitted laser energy within an endcap disposed on and optically coupled with the optical fiber, and directing laser energy output from the endcap onto a build surface to form a laser energy spot on the build surface. ### Claim 6 (depends on 5) The method of claim 5, wherein a surface area of a distal surface of the endcap is larger than a transverse cross sectional area of the distal end of the optical fiber. ### Claim 7 (depends on 5) The method of claim 5, further comprising focusing the laser energy transmitted from the endcap. ### Claim 8 (depends on 1) The additive manufacturing system of claim 1, wherein the distal end of the optical fiber is fused with the endcap. ### Claim 9 (depends on 1) The additive manufacturing system of claim 1, further comprising one or more lenses disposed downstream from and optically coupled to the endcap. ### Claim 10 (depends on 1) The additive manufacturing system of claim 1, wherein the endcap is selected from the group of a cylinder, a prism, and a microlens. ### Claim 11 (depends on 1) The additive manufacturing system of claim 1, wherein the endcap comprises multiple microlens portions. ### Claim 12 (depends on 1) The additive manufacturing system of claim 1, wherein an axial position of the distal end of the endcap is within 20 microns of a predetermined axial position. ### Claim 13 (depends on 5) The method of claim 5, wherein the distal end of the optical fiber is fused with the endcap. ### Claim 14 (depends on 5) The method of claim 5, further comprising one or more lenses disposed downstream from and optically coupled to the endcap. ### Claim 15 (depends on 5) The method of claim 5, wherein the endcap is selected from the group of a cylinder, a prism, and a microlens. ### Claim 16 (depends on 5) The method of claim 5, wherein the endcap comprises multiple microlens portions. ### Claim 17 (depends on 5) The method of claim 5, wherein an axial position of the distal end of the endcap is within 20 microns of a predetermined axial position. ### Claim 18 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 an array of laser energy spots on the build surface; a plurality of optical fibers optically coupled with the plurality of laser energy sources; and one or more endcaps disposed on and optically coupled with a distal end of each optical fiber, wherein each endcap of the one or more endcaps has a surface area of a distal surface that is larger than a transverse cross-sectional area of the distal ends of the optical fibers disposed thereon, wherein the plurality of optical fibers forms an array. ### Claim 19 (depends on 18) The additive manufacturing system of claim 18, wherein the one or more endcaps are configured to increase a transmission area of laser energy transmitted from the plurality of laser energy sources to reduce a power area density of the transmitted laser energy. ### Claim 20 (depends on 18) The additive manufacturing system of claim 18, wherein the distal end of each optical fiber is fused with the one or more endcaps. ### Claim 21 (depends on 18) The additive manufacturing system of claim 18, further comprising one or more lenses disposed downstream from and optically coupled to the one or more endcaps. ### Claim 22 (depends on 18) The additive manufacturing system of claim 18, further comprising an alignment fixture configured to position and orient the one or more endcaps. ### Claim 23 (depends on 22) The additive manufacturing system of claim 22, wherein the alignment fixture comprises v-grooves. ### Claim 24 (depends on 18) The additive manufacturing system of claim 18, wherein the array is a linear array. ### Claim 25 (depends on 18) The additive manufacturing system of claim 18, wherein the array is a two-dimensional array. ### Claim 26 (depends on 18) The additive manufacturing system of claim 18, wherein two or more optical fibers of the plurality of optical fibers are optically coupled to a single endcap of the one or more endcaps. ### Claim 27 (depends on 18) The additive manufacturing system of claim 18, wherein each optical fiber of the plurality of optical fibers is optically coupled to a separate endcap of the one or more endcaps. ### Claim 28 (depends on 18) The additive manufacturing system of claim 18, wherein each endcap of the one or more endcaps is selected from the group of a cylinder, prism, and a microlens. ### Claim 29 (depends on 18) The additive manufacturing system of claim 18, wherein an axial position of a distal end of each endcap of the plurality of endcaps is within 20 microns of a predetermined axial position. ### Claim 30 (depends on 18) The additive manufacturing system of claim 18, wherein the one or more endcaps comprise at least one endcap that includes multiple microlens portions.