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

附加制造(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。Industry 4.0旨在更新制造实践，通过创意、智能和连接将其带入数字世界。通过允许用户访问3D打印机，直接数字制造是工业4.0的关键驱动因素，为定制部件提供快速周转并减少对环境的影响。现在，设计、订购和交付在24小时内成为可能。这一不断扩大的领域有可能彻底改变人类生活的方方面面。可以通过3D打印制造的塑料和金属部件可以显著减少制造过程中的浪费，以及减轻部件运输的重量(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(如整形外科植入物)生产单独定制的部件，从而提高生活质量，而不是一刀切的方法。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系统在床上重复沉积一层金属粉末，然后高功率激光在表面上扫描，只熔化需要在下面层上沉积金属的区域，类似于用钢笔写字。这是一层又一层的重复，构建了一个完整的3D结构。SLM系统价格昂贵，以这种方式制造的部件60%的成本与时间相关，阻碍了这些系统的部署。我们将开发一种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。这项工作的新奇之处在于基于纳米尺度上的光子(光控制)结构开发了新的激光系统。这些新的激光阵列可以一次写入整个层，而不是一次写入一个光点。然后，使用我们的一维阵列SLM系统可以将制造完整的3D零件的速度提高4到10倍，使用我们的2D阵列SLM系统可以加快10到100倍。我们预测，这一时间和成本的降低将为加法制造带来印刷机对出版的影响。

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.