TY - JOUR

T1 - Polymer-based 3D printing of function-integrated optomechanics

T2 - design guidelines and system evaluation

AU - Kranert, Fabian

AU - Hinkelmann, Moritz

AU - Lachmayer, Roland

AU - Neumann, Jörg

AU - Kracht, Dietmar

N1 - Publisher Copyright: © 2024, Fabian Kranert, Moritz Hinkelmann, Roland Lachmayer, Jörg Neumann and Dietmar Kracht.

PY - 2024/8/28

Y1 - 2024/8/28

N2 - Purpose: This study aims to extend the known design guidelines for the polymer-based fused filament fabrication (FFF) 3D printing process with the focus on function-integrated components, specifically optomechanical parts. The potential of this approach is demonstrated by manufacturing function-integrated optomechanics for a low-power solid-state laser system. Design/methodology/approach: For the production of function-integrated additively manufactured optomechanics using the FFF process, essential components and subsystems have been identified for which no design guidelines are available. This includes guidelines for integrating elements, particularly optics, into a polymer structure as well as guidelines for printing functional threads and ball joints. Based on these results, combined with prior research, a function-integrated low-power solid-state laser optomechanic was fabricated via the FFF process, using a commercial 3D printer of the type Ultimaker 3. The laser system's performance was assessed and compared to a reference system that employed commercial optomechanics, additionally confirming the design guidelines derived from the study. Findings: Based on the design goal of function integration, the existing design guidelines for the FFF process are systematically extended. This success is demonstrated by the fabrication of an integrated optomechanic for a solid-state laser system. Practical implications: Based on these results, scientists and engineers will be able to use the FFF process more extensively and benefit from the possibilities of function-integrated manufacturing. Originality/value: Extensive research has been published on additive manufacturing of optomechanics. However, this research often emphasizes only cost reduction and short-term availability of components by reprinting existing parts. This paper aims to explore the capabilities of additive manufacturing in the production of function-integrated components to reduce the number of individual parts required, thereby decreasing the workload for system assembly and leading to an innovative production process for optical systems. Consequently, where needed, it provides new design guidelines or extends existing ones and verifies them by means of test series.

AB - Purpose: This study aims to extend the known design guidelines for the polymer-based fused filament fabrication (FFF) 3D printing process with the focus on function-integrated components, specifically optomechanical parts. The potential of this approach is demonstrated by manufacturing function-integrated optomechanics for a low-power solid-state laser system. Design/methodology/approach: For the production of function-integrated additively manufactured optomechanics using the FFF process, essential components and subsystems have been identified for which no design guidelines are available. This includes guidelines for integrating elements, particularly optics, into a polymer structure as well as guidelines for printing functional threads and ball joints. Based on these results, combined with prior research, a function-integrated low-power solid-state laser optomechanic was fabricated via the FFF process, using a commercial 3D printer of the type Ultimaker 3. The laser system's performance was assessed and compared to a reference system that employed commercial optomechanics, additionally confirming the design guidelines derived from the study. Findings: Based on the design goal of function integration, the existing design guidelines for the FFF process are systematically extended. This success is demonstrated by the fabrication of an integrated optomechanic for a solid-state laser system. Practical implications: Based on these results, scientists and engineers will be able to use the FFF process more extensively and benefit from the possibilities of function-integrated manufacturing. Originality/value: Extensive research has been published on additive manufacturing of optomechanics. However, this research often emphasizes only cost reduction and short-term availability of components by reprinting existing parts. This paper aims to explore the capabilities of additive manufacturing in the production of function-integrated components to reduce the number of individual parts required, thereby decreasing the workload for system assembly and leading to an innovative production process for optical systems. Consequently, where needed, it provides new design guidelines or extends existing ones and verifies them by means of test series.

KW - 3D printed optomechanics

KW - 3D printing

KW - Additive manufacturing

KW - Design guidelines

KW - Fused filament fabrication

UR - http://www.scopus.com/inward/record.url?scp=85203423585&partnerID=8YFLogxK

U2 - 10.1108/RPJ-02-2023-0073

DO - 10.1108/RPJ-02-2023-0073

M3 - Article

AN - SCOPUS:85203423585

VL - 30

SP - 246

EP - 258

JO - Rapid prototyping journal

JF - Rapid prototyping journal

SN - 1355-2546

IS - 11

ER -