Scalable Adaptive Laser Array for Additive Manufacturing (SALAAM)

The proposed Scalable Adaptive Laser Array for Additive Manufacturing (SALAAM) concept is based on emerging high-power coherent fiber array and adaptive beam control technologies that have been under development by the Optonicus for DoD (directed energy) applications for almost a decade. In the SALAAM approach, the multiple beams for LAM are generated in a coherent fiber-collimator array system that is composed of a densely packed array of adaptive fiber-collimators, with integrated capabilities for individual precision beam pointing and steering using Optonicus-developed fiber-tip x-y position control modules. The proposed SALAAM energy source with multiple laser beams and feedback sensors provides a new breakthrough advanced spatiotemporal control of energy flux for AM in metals. This development will also provide first transitioning of the DoD high energy laser weapon technology to industrial applications including additive manufacturing and advanced laser material processing with multi-kW class laser systems (dissimilar material joining, welding, cutting, etc.).