A light-driven light valve for metal additive manufacturing

An optically addressable light valve is used for high repetition rate dynamic laser beam shaping used in a unique metal additive manufacturing process [1]. The resulting Area Printing™ delivers high power pulses - each with an individually controlled shape - to a metal powder bed that locally sinters and melts to consolidate into a fully dense metal part. This technology and device enable scaling cheaper additive manufacturing with high spatial resolution, while capable of printing part features beyond reach of conventional manufacturing, and with greater efficiency and minimal spatter defects. We address here the unique optoelectronic properties needed from the optically addressable photoresistor that controls the dynamic beam shaping for high density, high-resolution laser 3D printing. Further description is presented of the device-level thermomechanical analysis from parasitic absorption of the laser at kW to MW power levels. We thus highlight key areas of semiconductor properties challenging the performance capabilities in optically addressed light valves used in high power switching applications. [1] https://www.seurat.com/area-printing