Bright Laser diOdes fOr aDvance metaL addItive maNufacturing systEms (BLOODLINE)

增材制造（AM）或3D打印是一种使能技术，是数字化、本地化、低周转时间、个性化世界中制造业的未来。工业4.0旨在更新制造实践，通过创造力，智能和连接性将其带入数字世界。通过允许用户使用3D打印机进行直接数字化制造，是工业4.0的关键驱动力，可提供快速周转和减少环境影响的定制零件。设计、订购和交付现在可以在24小时内完成。这个不断扩大的领域有可能彻底改变人类生活的许多方面。可以通过3D打印制造的塑料和金属零件可以显着减少制造过程中的浪费，并减少运输零件的重量（减少航空航天等关键部门的碳排放）。这些系统还可以为医疗应用生产个性化定制的部件，如骨科植入物，通过一刀切的方法提高生活质量。选择性激光熔化（SLM）是制造金属部件的领先AM工艺。目前的SLM系统重复地将一层金属粉末存款在床上，然后高功率激光在表面上扫描，仅熔化下面层上需要金属沉积的区域，类似于用笔书写。这是一层一层地重复，构建一个完整的3D结构。SLM系统是昂贵的，并且以这种方式制造的部件的成本的60%是时间依赖性的，阻碍了这些系统的部署。我们将开发使用可单独寻址的直接二极管（iADD）半导体激光器阵列的快速3D打印技术。这项工作的新奇在于开发了基于纳米级光子（光控制）结构的新激光系统。这些新的激光阵列可以让整个层一次写入，而不是一次写入一个点。使用我们的1D阵列SLM系统，可以以4到10倍的速度构建完整的3D部件，而使用我们的2D阵列SLM系统，可以以10到100倍的速度构建完整的3D部件。我们预测，这种时间和成本的降低将为增材制造带来印刷机在出版业中的作用。

Additive manufacturing (AM), or 3D printing, is an enabling technology and is the future of manufacturing in a digital, local, low turnaround time, personalised world. Industry 4.0 aims to update manufacturing practice bringing it into the digital world through creativity, intelligence and connectivity. Direct digital manufacturing by allowing user access to 3D printing machines, is a key driver for industry 4.0, providing custom parts with rapid turn-around and reduced environmental impact. Designing, ordering, and delivery is now possible within 24 hours.This expanding field has the potential to revolutionise many aspects of human life. The plastic and metal parts which can be manufactured through 3D printing can significantly reduce waste during the manufacturing process, as well as reduce the weight of parts shipped (reducing carbon emission for key sectors such as aerospace). These systems can also produce individually tailored parts for medical applications, such as orthopaedic implants, giving improved quality of life over a one size fits all approach.Selective laser melting (SLM), is a leading AM process for making metal parts. Current SLM systems repeatedly deposit a layer of metal powder on a bed, then a high-power laser is scanned over the surface, melting only areas which require metal deposition on the layer below, akin to writing with a pen. This is repeated layer by layer, building a complete 3D structure. The SLM systems are expensive, and \>60% of the cost of the parts manufactured in this way are time dependant, holding back the deployment of these systems.We will develop a rapid 3D printing technology using individually addressable direct diode (iADD) semiconductor laser arrays. The novelty in this work is the development of new laser systems based on photonic (light controlling) structures pattered on the nanoscale. These new laser arrays can allow an entire layer to be written in one go instead of one spot at a time. The full 3D parts can then be built between 4 to 10 times faster using our 1D array SLM system and between 10 and 100 times faster using our 2D array SLM system.We predict that this time and cost reduction will do for additive manufacturing what the printing press did for publishing.