EP3579996A1 - Stratégie d'exposition dans des systèmes de fabrication additive (am) à faisceaux multiples - Google Patents

Stratégie d'exposition dans des systèmes de fabrication additive (am) à faisceaux multiples

Info

Publication number
EP3579996A1
EP3579996A1 EP18710421.1A EP18710421A EP3579996A1 EP 3579996 A1 EP3579996 A1 EP 3579996A1 EP 18710421 A EP18710421 A EP 18710421A EP 3579996 A1 EP3579996 A1 EP 3579996A1
Authority
EP
European Patent Office
Prior art keywords
layer
section
building material
beams
quality
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP18710421.1A
Other languages
German (de)
English (en)
Inventor
Martin Schade
Albert Fruth
Robert Achim DOMRÖSE
Maximilian Mittermüller
Michael KOVAL
Markus KUCHENBAUR
Michael GÖTH
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EOS GmbH
Original Assignee
EOS GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by EOS GmbH filed Critical EOS GmbH
Publication of EP3579996A1 publication Critical patent/EP3579996A1/fr
Pending legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/4097—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by using design data to control NC machines, e.g. CAD/CAM
    • G05B19/4099—Surface or curve machining, making 3D objects, e.g. desktop manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/10—Auxiliary heating means
    • B22F12/13—Auxiliary heating means to preheat the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B22F12/45—Two or more
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/49—Nc machine tool, till multiple
    • G05B2219/49013—Deposit layers, cured by scanning laser, stereo lithography SLA, prototyping
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/49—Nc machine tool, till multiple
    • G05B2219/49018—Laser sintering of powder in layers, selective laser sintering SLS
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P80/00—Climate change mitigation technologies for sector-wide applications
    • Y02P80/40—Minimising material used in manufacturing processes

Definitions

  • the invention relates to a device and a computer-aided method for generating a control data record for a generative layer construction device.
  • Generative layer construction devices and related methods are generally characterized by fabricating objects in them by solidifying a shapeless building material layer by layer.
  • the solidification may be effected by supplying heat energy to the building material by irradiating it with electromagnetic radiation or particle radiation (e.g., laser sintering (SLS) or laser melting or electron beam melting) or by causing a crosslinking reaction in the building material (e.g., stereolithography).
  • electromagnetic radiation or particle radiation e.g., laser sintering (SLS) or laser melting or electron beam melting
  • SLS laser sintering
  • crosslinking reaction in the building material e.g., stereolithography
  • the production time can be reduced if several energetic beams, eg laser beams, are used at the same time to solidify the one or more cross sections of the object in one layer.
  • WO 2016/110440 A1 describes a corresponding device in which different laser beams are assigned to different areas of a layer, wherein there are areas in which a plurality of beams can act on the building material, i. Areas to which not only one laser beam but several laser beams can be directed.
  • FIG. 12 illustrates this procedure on the basis of a construction field on which four laser beams can act simultaneously.
  • those regions in which only one of the four laser beams can be used during solidification are indicated by AI to A4.
  • Areas where two laser beams can be used together for solidification are indicated by the letter "B", and the numbers following the letters indicate which of the four laser beams (numbered 1 to 4) is used.
  • WO 2016/110440 A1 deals with the problem that it is necessary to coordinate which of the laser beams that can be used in a common area is directed to a specific location in this area.
  • the coordination can in particular be carried out so that a laser beam, in whose area of action only few points within a layer are to be solidified, can be used in an adjacent exposure area in which many points must be solidified.
  • the inventors have found that in the boundary region of the exposure zones of different laser beams, for example, in the region B12 in Fig. 12, at the boundary line G between the region B121 solidified by the laser beam 1 and the region B122 solidified by the laser beam 2 is, the Aufschmelz or solidification behavior of the building material is slightly different than in other areas.
  • the inventors were able to determine that slight inhomogeneities of the component properties occur at the borderline, for example deteriorated mechanical parameters.
  • the production time can be significantly reduced by using several laser beams, the Inventors found that when using multiple laser beams with losses in the quality of the manufactured objects must be expected.
  • an object of the present invention to provide an improved method and an apparatus for producing objects by means of a generative layer construction method, in particular an additive manufacturing method.
  • a computer-assisted method for generating a control data record for a generative layer building apparatus for producing a three-dimensional object by means of the same, the production comprising the steps:
  • the insertion means is adapted to direct a plurality of beams to different regions of an applied layer, each of the beams, where it strikes the layer, acting on the building material, in particular so as to solidify it,
  • the layer data set is modified such that is determined for at least a portion of the object cross-section, preferably automatically, in dependence on specifications for a quality of the section and / or a production time of the object, with which number of beam bundles the Building material within this section is solid, and
  • the modified shift data record is provided as a control data record for the generative layer building apparatus.
  • the radiation source may, for example, be a laser or an electron beam source, but it would also be conceivable for a device for 3D printing which produces a binder beam (even if the term "radiation” is rather seldom used in this context) or a UV radiation.
  • Light source in stereo The term “beam” is intended to express that not only rays are meant that have a small or round cross section when hitting the building material, but also rays that z. B. have a line-shaped cross-section or even radiation, which is registered at the same time in a larger area of the building material (ie flat).
  • a data record which contains a data model of a build-up material layer to be consolidated at the locations of an object cross-section during the production process is regarded as a shift data record.
  • a data model has a two-dimensional representation of the object cross-section to be consolidated in a layer by means of one or more beam bundles.
  • the layer data set can, but need not, even more information regarding the production of the object cross section may be included, for. B. the layer thickness, the diameter of an incident on the building material beam, etc.
  • a production process is automatically adapted to the quality and / or speed specifications for individual or all sections of an object cross-section.
  • the quality of a manufactured object or object section is influenced by a large number of boundary conditions during production: the quality of the building material, the existing environmental parameters (eg a temperature or temperature distribution in the installation space), apparatus peculiarities of the generative layer construction device (eg. Variations in the optical properties of the beam shaping optics and / or in the size or shape of an incident surface of a beam and / or in an energy distribution over an incident surface of a beam within the construction field), etc.
  • the inventors of the present application have recognized here that also the number of beams used to solidify an object section affects the quality.
  • quality as understood in the present application describes the range of properties, e.g. Density, of an object, in other words, to what extent an object property varies across the object. It is true that object properties are always scattered in reality. However, at high quality, a desired object property will vary only slightly across the object or from object to object. At low quality, the desired property will vary widely, ultimately giving less control over the property, e.g. Eg about whether the density has a certain value.
  • a quality can be specified by specifying one or more quality indicators, which are assigned values that are considered as a measure of the quality, eg. B. Limits for certain object properties or process parameters that characterize the manufacturing process by means of a generative Schichtbauvorraum.
  • object properties are mechanical parameters, such as tensile strength, breaking strength, the porosity of the consolidated building material, the microstructure, in particular the crystal structure, a degree of contamination in the material, on the surface texture related parameters such.
  • the quality of a manufactured object or object section in the sense of the present invention can be regarded as homogeneity of the manufactured object or object section.
  • High homogeneity is associated with high quality within the scope of the invention.
  • homogeneity it is meant that fluctuations of object properties (in particular abrupt changes) remain below a predefined limit with regard to their absolute values or statistical fluctuations. This may mean, for example, that abrupt changes of certain properties within a manufactured object or from object to object (in the case of several objects produced in parallel), which may occur despite keeping the corresponding control data of the generative layer building apparatus constant, will not exceed a certain extent with high probability become.
  • the best possible number of hardening bundles to be used is automatically selected for the given boundary conditions (quality and production time). This means that even if the target production time is as short as possible, quality to be prevented. In particular, this can be made with high quality (or homogeneity) only in predetermined sections, where this is considered necessary, while in other sections, the time required for solidification of the building material is minimized. In this way, individual requirements can be reacted to in the production of a specific object.
  • the respective exposure strategies for the respective hardening beam bundles it is additionally possible to determine the respective exposure strategies for the respective hardening beam bundles. This is e.g. It is meant a definition of subregions of an object section assigned to the individual hardening beam bundles and / or a determination of the respective temporal and spatial patterns with which the hardening beam bundles are moved over the subregions assigned to them.
  • a shift data record is accessed which has a data model in which corresponding points are identified for the cross sections of a plurality of objects in the associated build material layer. are characterized in which a solidification of the building material to take place, in which case the layer data set is modified in such a way that for at least two sections which are assigned to the cross sections of different objects, depending on specifications for a quality of the section and / or a Production time of the object, it is preferably automatically determined with what number of beams the building material is to be solidified within each of these sections.
  • the layer data set is preferably modified in such a way that, for each of the sections corresponding to the section, taking into account the definition according to the second step, the beam material is used to consolidate the building material at this point is.
  • this determination is made in advance in determining the number of beams to be used.
  • this definition can be integrated in the second step.
  • a control data set for a generative layer construction device is generated, which is designed such that n beam bundles can be simultaneously directed to a layer of the building material, where n is a natural number greater than one.
  • a production time which is as short as possible is achievable, in particular, with generative layer construction devices in which a simultaneous solidification takes place with a plurality of beam bundles.
  • the method is particularly preferred in connection with a generative Layering apparatus applied, which is designed so that four beams can be directed simultaneously to a layer of the building material.
  • the use of a large number of beam bundles leads to high demands on the coordination of the different beam bundles and, on the other hand, when using a plurality of radiation sources, at significantly higher costs of the generative layer construction device.
  • the utility of four beams simultaneously in the generative layering device is a good compromise between achievable manufacturing times and the cost of the device.
  • an operator for specifying the quality or homogeneity by means of an operator input at an input terminal, in particular a graphical user interface selects one of n predetermined successive quality or homogeneity levels.
  • n is a natural number greater than one and is preferred, but not necessarily, equal to the number of existing beam bundles in the generative layer building apparatus.
  • the predetermined quality or. Homogeneity levels of an order relation are subject and all to each other are different. The specification of discrete homogeneity levels facilitates on the one hand the operability and on the other hand the adaptability of the method according to the invention to a given generative layer building apparatus.
  • the build-up material within this section is to be solidified with a number of beam bundles that is greater than one and less than the maximum number of beam bundles , wherein for a higher quality or homogeneity level in each case the number of beams to be used is less than or equal to the number of beams to be used for a lower quality or homogeneity level.
  • the approach is based on the idea that with increasing number of bundles used in a section for solidification also increases the number of border areas and correspondingly decreases the homogeneity.
  • the number of beams to be used falls monotonously with increasing homogeneity level.
  • the number of actually used for the consolidation of a section beam can be chosen inversely proportional to the predetermined homogeneity level.
  • a production time for the production of the object is preferably specified by the operator and an error message is output to the operator, in particular via a graphical user interface, if such specified quality or homogeneity and the specified production time not compatible with each other, ie not both can be achieved at the same time.
  • an operator already receives information prior to the start of a production process that production of the object is not possible with the planned boundary conditions (homogeneity and production time). As a result, costs can be saved because vain attempts to produce the object with incompatible boundary conditions are avoided.
  • the specifications for a quality or homogeneity of an object to be produced from the existing information in the shift record in particular a level of detail of a data model of the object to be produced, a shape of the individual object cross-sections and / or a manner in which the radiation the building material is supplied and / or derived from a type and / or nature of the building material.
  • the process can run fully automatically, without the input of an operator are necessary.
  • information is used in the shift data record as well as additional information by the operator (for example, the specification of a maximum production time) are used for the determination in the second step.
  • specifications are taken into account for a section of the object to be produced, preferably for the entire object to be produced. If the homogeneity and / or production time are specified not only for a section of an object cross-section but also for an entire object cross-section, a section of the object extending over parts of several object cross-sections, or even the entire object, then simplifications may result insofar as then It is not necessary to predefine specifications for many individual sections of object cross sections, but only for larger subregions of an object, so that then the definition of the number of beams to be used for the hardening depends on whether the area to be solidified is within the object subregion (for the eg a high degree of homogeneity has been specified) or not.
  • the operator specifies only one production time for the production of the object, and an expected quality or homogeneity level for the object to be produced is output to the operator, which would be achieved within the predetermined production time when the object is manufactured.
  • z. B. first determined with what number of beams must be solidified in order to meet the specified (maximum) manufacturing time can.
  • an estimate of the expected homogeneity is made on the basis of the number of bundles to be used jointly for the consolidation of a section, and a homogeneity level resulting from the estimation is output to the operator.
  • an operator already receives information about the expected homogeneity before the start of a production process, whereby unnecessary manufacturing processes (since the expected homogeneity may not be acceptable) can be avoided.
  • a plurality of adjoining partial cross-sections, that is to be solidified subregions of this section are defined in at least one section, for the second step, a solidification is set with a plurality of beam bundles, wherein for each of the partial cross-sections is determined with which beam bundle the points in this partial cross section are to be solidified, wherein the partial cross sections are defined so that a boundary region, ie a region lying at the boundary between different partial cross sections, in its shape and / or position in the layer plane with respect to the shape and / or position a boundary region in one of the immediately preceding or the immediately following layer associated layer data set is different.
  • a generative layer construction method for producing a three-dimensional object by means of a generative layer construction apparatus, the production comprising the steps:
  • the insertion device is designed to direct a plurality of bundles of rays, in particular simultaneously, to different regions of the applied layer, each of the bundles of rays, where it impinges on the layer, acting on the building material, in particular in such a way that it is solidified,
  • a manufacturing process with regard to production time and quality or homogeneity of an object to be produced can be optimized, for example by the inventive method for generating a control data set before the start of the manufacturing process, in particular before the application of the first building material layer is executed and controlled the flow of the manufacturing process of a control instruction set which contains the control data record provided by the method according to the invention for generating a control data record.
  • the inventive method for generating a control data record during the production of the three-dimensional object can be carried out, so that the Solidification constraints can be set dynamically for optimization of homogeneity and production time.
  • a generative layer construction device has a control device which controls a production process of an object using a control data record generated by a method according to the invention.
  • An apparatus for computer-aided generation of a control data set for a generative layer building apparatus for producing a three-dimensional object by means of the same, the production comprising the steps:
  • the insertion device is designed to direct a plurality of bundles of rays, in particular simultaneously, to different regions of the applied layer, each of the bundles of rays, where it impinges on the layer, acting on the building material, in particular in such a way that it is solidified,
  • an access unit adapted to access a shift record that includes
  • the device according to the invention for generating a control data set is suitable for carrying out any of the variants of the method according to the invention for generating a control data record.
  • the access unit mentioned can be an input interface which can read data from a mobile data carrier or receives data via a network or else reads out data directly from a memory.
  • the device according to the invention can not only be implemented as a separate unit, but can also be part of a more comprehensive EDP system (for example of a CAD design system) or integrated into a generative layer construction device. In the latter two cases, the access unit is then preferably a software interface that communicates with other system components.
  • the device according to the invention does not necessarily have to be part of a generative layer construction device. This is advantageous because it is possible that layer data sets for an object to be processed are not present at the location of the generative layer construction device, but rather where the object to be processed has been designed.
  • the access unit can also access layer data records which are stored in a memory present in the device according to the invention.
  • a close coupling of the device according to the invention for generating a control data set to a generative layer construction device, for which the control data set is generated is advantageous, because then quickly given by the generative layer construction device predetermined technical boundary conditions (eg Process parameters, such as the installation space temperature, etc.) can be reacted.
  • predetermined technical boundary conditions eg Process parameters, such as the installation space temperature, etc.
  • the device according to the invention preferably additionally contains a data alteration unit which is suitable in the layer data modified by the definition unit. for each of the sections corresponding to the section, by means of which beam the building material is to be solidified at this point.
  • a data alteration unit which is suitable in the layer data modified by the definition unit. for each of the sections corresponding to the section, by means of which beam the building material is to be solidified at this point.
  • a computer program according to the invention comprises program code means for carrying out all steps of a method according to the invention for generating a control data set or a generative layer construction method according to the invention, when the computer program is executed on a data processor, in particular a data processor cooperating with a generative layer construction device.
  • "Interaction" means that the data processor is either integrated into the generative layer construction device or can exchange data with it.
  • FIG. 1 shows a schematic, partially sectional view of an exemplary apparatus for generatively producing a three-dimensional object according to an embodiment of the invention
  • 2 and 3 each show a schematic plan view of a partial region of the construction field of a generative layer construction device for explaining the procedure according to the invention
  • FIG. 4 shows a schematic illustration of a computer-assisted method according to the invention for generating a control data set for a generative layer construction device
  • FIG. 5 shows the schematic structure of a device for generating a control data record according to the present invention
  • FIG. 6 shows the schematic structure of a modified device for generating a control data record according to the present invention
  • FIG. 7 shows a schematic representation of a computer-assisted method according to the invention for generating a control data record by means of the modified device of FIG. 6,
  • FIG. 7 shows a schematic representation of a computer-assisted method according to the invention for generating a control data record by means of the modified device of FIG. 6,
  • FIG. 7 shows the schematic structure of a modified device for generating a control data record according to the present invention
  • FIG. 8 shows an exemplary graphical control element for specifying a quality or homogeneity by an operator
  • FIG. 9 shows an exemplary graphical control element for prescribing a production time by an operator
  • FIG. 10 shows an exemplary graphical control element for prescribing quality or homogeneity and production time by an operator
  • 11 shows a schematic plan view of a partial area of the construction field of a generative layer construction device for explaining the procedure according to the invention for the contour area
  • 12 shows a schematic plan view of a construction field of a generative layer construction device for explaining the procedure in the presence of a plurality of solidification beams
  • the laser sintering or laser melting device 1 contains a process chamber or construction chamber 3 with a chamber wall 4.
  • an upwardly open building container 5 is arranged with a container wall 6.
  • a working plane 7 is defined by the upper opening of the construction container 5, wherein the area of the working plane 7 which lies within the opening and which can be used to construct the object 2 is referred to as construction field 8.
  • a movable in a vertical direction V carrier 10 is arranged, on which a base plate 11 is mounted, which closes the container 5 down and thus forms its bottom.
  • the base plate 11 may be a plate formed separately from the carrier 10, which is fixed to the carrier 10, or it may be integrally formed with the carrier 10.
  • a building platform 12 can still be mounted on the base plate 11 as a construction base on which the object 2 is built up.
  • the object 2 can also be built on the base plate 11 itself, which then serves as a construction document.
  • Fig. 1 is to be formed in the container 5 on the building platform 12
  • the laser sintering or melting apparatus 1 further comprises a reservoir 14 for a building material 15, in this example an electromagnetic radiation solidifiable powder, and a coater 16 movable in a horizontal direction H for applying the building material 15 within the construction field 8 the process chamber 3, a radiant heater 17 may be arranged, which serves for heating the applied building material 15.
  • a radiant heater 17 for example, an infrared radiator can be provided.
  • the exemplary Lasersintervorrichtu ng 1 further includes an exposure device 20 with a laser 21, which generates a laser beam 22 which is deflected by a deflecting device 23 and d by a focusing device 24 via a coupling window 25, which at the top of the process chamber 3 in the chamber wall. 4 is attached, is focused on the working plane 7.
  • the laser sintering device 1 includes a control device 29, via which the individual components of the device 1 are controlled in a coordinated manner for carrying out the building process.
  • the control device 29 may also be mounted partially or completely outside the device.
  • the controller may include a CPU whose operation is controlled by a computer program (software).
  • the computer program can be stored separately from the device on a storage medium, from which it can be loaded into the device, in particular into the control device.
  • an exposure device may include, for example, one or more gas or solid state lasers or any other type of laser, such as laser diodes, in particular Vertical Cavity Surface Emitting Laser (VCSEL) or Vertical External Cavity Surface Emitting Laser (VECSEL), or a line include this laser.
  • VCSEL Vertical Cavity Surface Emitting Laser
  • VECSEL Vertical External Cavity Surface Emitting Laser
  • any device can be used with which energy can be selectively applied to a layer of the building material as electromagnetic radiation or particle radiation.
  • a laser it is possible, for example, to use another light source, an electron beam or any other source of energy or radiation that is suitable for solidifying the building material.
  • the specific structure of a laser sintering or melting device shown in FIG. 1 is therefore only an example and can of course also be modified, in particular when using a different exposure device than the one shown.
  • Fig. 1 as an example of a generative Schichtbauvoriques a Lasersinter point. Laser melting device has been described, the invention is not limited to the laser sintering or laser melting.
  • the exposure device 20 is replaced by another insertion device depending on the method, in the case of a 3D printing process by a device which injects one or more binder beams onto the building material, in the case of a stereolithography process by a UV light source.
  • the entry device contains any type of radiation source from which at least one beam impinging on the construction material is directed.
  • a generative layer construction device in which an entry device is set up in such a way that it receives a plurality of beams or beams.
  • a generative layer construction device to which the invention relates may comprise a plurality of radiation sources 21, wherein preferably, but not necessarily, each radiation beam or beam is assigned its own radiation source.
  • FIG. 1 shows only a single exposure device 20 with a single radiation source 21 and a single beam 22.
  • various materials can be used, preferably powder or pastes or gels, in particular metal powder, but also plastic powder, ceramic powder or sand, whereby the use of filled or mixed powders is also possible.
  • plastic powder, ceramic powder or sand Especially in stereolithography (liquid) photopolymers are used.
  • a control operation is carried out such that the control unit 29 executes a control instruction set which is instructions to successively apply layers of the building material and areas of the respective layers corresponding to the cross section of an object to be manufactured, selectively irradiated with the laser radiation to solidify the building material.
  • the control instruction set thus contains information about the points to be consolidated within a layer and the type of decomposition of the object to be produced into layers.
  • control command set is based on a computer-based model of the object (s) to be produced, preferably a CAD solid model. Furthermore, production-specific information, for example the situation, also flows into the control instruction set and orientation of the objects in the container 5 or a beam diameter when a laser beam strikes the building material. Finally, the control command set also contains the layer information, that is to say in which way the object or objects to be produced are subdivided into layers that correspond to the building material layers during the layer-by-layer, generative production.
  • the control instruction set defines, in particular, the thickness of the layer application and the locations at which solidification of the building material is to be effected by irradiation for each building material layer during production.
  • the control instruction set can thus be regarded as a totality of all control data predetermined for the control of the production process in a generative layer construction device.
  • the control data related to a single layer are also referred to as a shift data record.
  • the control command set also contains all the data required for controlling the exposure device, which, inter alia, determines the energy density of the radiation emitted by the exposure device and optionally the travel speed of the beam via the construction field 8.
  • a device 100 for generating a control data record for a specific generative layer construction device contains an access unit
  • FIG. Figures 2 and 3 each show a plan view of a partial area of the construction field 8 of a generative layer construction apparatus in which the working areas of four solidification beams or bundles of rays, ie the locations in the construction field to which the solidification beams or bundles of rays can respectively be directed, are represented are.
  • A designates those regions in which only one solidification jet, eg, a hardening jet, e.g. For example, a laser beam can be used in the consolidation.
  • FIGS. 2 and 3 show, by way of example, a parallelogram-shaped object cross-section 55 of an object to be produced, which is to be solidified during the production process in a layer k of the building material.
  • FIGS. 2 and 3 show in each case a plan view of the layer k of the building material.
  • an access unit 101 accesses a layer data record of the object to be produced in a first step for carrying out the computer-assisted method according to the invention. In the process sequence shown in FIG. 4, this is step S1.
  • the term access means that the access unit 101 reads out a shift data record from a memory or else accepts the data corresponding to the shift data record via a network. Likewise, the access unit can also access a memory in the device 100 in which the shift data record is stored.
  • a layer data set must first contain information only for the associated building material layer at which points of the building material layer during the manufacture of the object, a solidification of the build material is to be effected by directing beam to the building material layer.
  • process information eg layer thickness or beam diameter, etc. may already be included.
  • the inventors have recognized that the number of beams (eg laser beams) used within a section of an object cross-section for the consolidation of the building material has an effect on the homogeneity of the object in this section.
  • the greater the number of sets used for consolidation In general, the homogeneity of the bundle of rays will be poorer, although, of course, the time required to solidify the section (ie the manufacturing time) will decrease as the number of beams increases.
  • the definition data unit 102 modifies the layer data record in such a way that at least one section of the object cross-section is determined as a function of specifications for a homogeneity of the section and / or a production time of the object with which Number of beams is to consolidate the building material within this section.
  • Figures 2 and 3 show here two possible results of the determination. For the sake of simplicity, it is assumed here that the cut, for which the determination is made in step S 2, encompasses the entire object cross-section 55.
  • FIG. 2 illustrates the case in which the shortest possible production time has been predetermined.
  • the action areas 31, 32, 33, 34 of the four beam bundles 1000, 2000, 3000, 4000 can be seen.
  • Boundary regions 35, 36, 37, 38 separate the areas of action from one another.
  • the border areas are lines of magnitude.
  • the term "boundary area" was chosen.
  • any real line can be considered an area.
  • Fig. 3 illustrates the case in which for the object cross-section 55 a fairly high accuracy has been specified. Accordingly, it has been determined by the determining unit 102 that only two bundles of rays are used for the solidification of the object cross-section, although more bundles of rays would have been available. It can be seen in Fig. 3, the Einwirk Societye 42 and 43 of the beam 2000 and 3000, through the boundary region 45th are separated from each other. Due to the presence of only one boundary region 45, after solidification there are fewer inhomogeneities in the object cross-section of FIG. 3 compared to the case of FIG. 2. In a step S3 shown in FIG.
  • a control data record can be regarded as a subset of a control instruction set of a generative layer building apparatus.
  • a control data set provided by the providing unit 103 can also be integrated by the providing unit 103 itself into a control instruction set.
  • provisioning also includes forwarding the control data record to a data processing device which integrates the control data record into a control command record, or a direct forwarding to a generative layering device. In particular, it is possible to dynamically provide control data for object cross sections still to be produced during a manufacturing process in the generative layer construction device.
  • modified layer data sets according to the invention need not be provided individually for a generative layer construction process. Rather, several modified shift data sets can first be collected and then, in their entirety, as
  • FIG. 6 shows a modified device 100a according to the invention for generating a control data record for a generative layer construction device
  • FIG. 7 shows a correspondingly modified method. If one compares the device in FIG. 6 with that in FIG. 5, one additionally recognizes in FIG. 6 a data modification unit 102a.
  • This carries out a step S23 illustrated in FIG. 7, in which the shift data record is modified in such a way that for each of the points corresponding to the section, taking into account the definition according to the second step S2, by means of which beam bundles the build-up material at this point to solidify.
  • the determining unit 102 as described above, in the most general embodiment of the invention, determines only the number of beams to be used for solidifying the portion in step S2.
  • the vorgenom by the operator settings with respect to homogeneity and / or manufacturing Kings Kings nen z. B. are stored in a memory to which the setting unit 102 then accesses.
  • the specifications are made stepless, but it is advisable, the operator discrete levels for the requirements of homogeneity and / or production time, since the possible number of beams to be used in the consolidation of a section also has discrete values.
  • this is already taken into consideration. For example, in FIGS. 8 to 10, one recognizes five discrete quality or homogeneity levels A, B, C, D, E and five discrete stages T 1, T 2, T 3, T 4, T 5 for the production time.
  • the determination of the number of the beam bundles to be used by the fixing unit 102 preferably takes place as a function of preliminary tests on a generative layer construction device of the same type as that by means of which the production of the object is planned. Ideally, the sections of similar objects were solidified in preliminary trials with different numbers of beams and analyzed for homogeneity and manufacturing time required. However, if such special information is lacking, then the procedure of the determining unit 102 may also be based on the experience of those skilled in the generative layer fabrication of objects. In particular, it is also possible to simulate the manufacturing process and to determine the number of beam bundles to be used for specific specifications on the basis of the simulation.
  • the results of the preliminary tests or simulations or else empirical values are available in the form retrievable for the setting unit 102, for example in the form of a table stored in a memory, which determines a relation between the number of beams to be used and the specified quality or homogeneity level and / or
  • the fixing unit 102 when specifying the lowest possible homogeneity level and / or the lowest possible production time, the fixing unit 102 will normally specify the maximum possible number of beams and given the highest possible homogeneity level and / or the maximum production time, the fixing unit 102 will normally set a solidification with only one beam.
  • the number of predetermined homogeneity levels and / or the number of predetermined stages for the manufacturing time equal to the maximum number of beams that are available for the solidification of a portion of an object cross-section or an entire object cross-section
  • a bijective Allocation of predetermined levels and numbers of beams to be used are carried out, in which the number of beams to be used is determined inversely proportional to the predetermined level for the homogeneity and / or production time.
  • an expected production time in the case of the invention
  • an expected production time can be optionally generated by the device 100 or 100a according to the invention for generating a control data record prior to the actual generation thereof Specification of homogeneity) or an expected homogeneity (in the case of specification of the production time), in order to give the operator the opportunity to change his specification.
  • it is first determined, for example, with which number of beam bundles it is necessary to consolidate in order to be able to comply with the specified (maximum) production time or to be able to achieve the specified homogeneity.
  • an estimate of the expected homogeneity is made and the operator is given a homogeneity level resulting from the estimation or an estimate of the expected production time and an estimate of the expected time resulting production time (level) output. If an operator specifies both the homogeneity and the production time, optionally the operator may be shown the incompatibility of his specifications. For example, high homogeneity and low production time could not be realized together. It can first be determined with which number of beams must be solidified in order to comply with the specified (maximum) manufacturing time can and then can be determined with what number of beams the specified homogeneity can be achieved.
  • the hardening behavior eg a melt pool diameter
  • a shape of an object cross-section in particular also a detail resolution, with which this object cross-section is characterized in a layer data record, allows conclusions to be drawn as to whether the detailed resolution can be fully realized in the production in view of the material and the solidification behavior predetermined by the solidification conditions. However, this can be used to estimate which object quality can actually be realized, and this homogeneity can be used as a guideline for determining the number of beam bundles to be used.
  • the relationships in the interior of an object cross section have been illustrated in particular in FIGS. 2 and 3, the present invention can likewise be applied to sections of an object cross section that lie in the contour of the object cross section. This case is illustrated in FIG. 11.
  • FIG. 11 The illustration in FIG. 11 is similar to that of FIGS. 2 and 3 and illustrates an object cross-section 95 in a layer k. Different from FIGS. 2 and 3, in FIG. 11 not the entire object cross-section 95 is considered as a section for which a determination is made, but only the contours of this object cross-section. 11 shows an exemplary result of a determination of the fixing unit 102, according to which the contour area (edge) of the object cross section 95 is solidified by means of two beams 2000 and 3000, which respectively solidify a partial section 92 or 93 of the contact area.
  • a contour region is usually solidified such that the solidification beam used, which has a certain diameter where it meets the build material, moves down the contour, so it is permissible to refer to sections of the contour of an object cross-section as two-dimensional regions.
  • the two boundary points 9392 and 9293 in Figure 11 are referred to as boundary areas.
  • a device according to the invention for generating a control data set of a generative layer construction device is not limited only by software but can also be realized solely by hardware components or mixtures of hardware and software.
  • interfaces mentioned in the present application do not necessarily have to be designed as hardware components, but can also be realized as software modules, for example, if the data fed in or output therefrom can be taken over by other components already realized on the same device or to a user other components only have to be transferred by software.
  • the interfaces could consist of hardware and software components, such as a standard hardware interface specifically configured by software for the specific application.
  • several interfaces can also be combined in a common interface, for example an input-output interface.

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Abstract

L'invention concerne un procédé assisté par ordinateur pour générer un ensemble de données de commande pour un dispositif de fabrication additive par couches, dans lequel l'objet est fabriqué couche par couche et par orientation d'une pluralité de faisceaux de rayonnement (22) sur différentes régions d'une couche déposée. Au cours d'une première étape (SI), le procédé consiste à accéder à un ensemble de données de couche comprenant un modèle de données d'une couche de matière additive à consolider sélectivement pendant le processus de production, des emplacements correspondant à une section transversale de l'objet, au niveau desquels une consolidation de la matière additive (15) doit se produire, étant caractérisés dans le modèle de données. Au cours d'une deuxième étape (S2), l'ensemble de données de couche est modifié de manière à pouvoir déterminer, pour au moins une partie de la section transversale de l'objet, de préférence automatiquement, en fonction de prescriptions pour atteindre une certaine qualité de ladite partie et/ou un temps de production de l'objet, quelle est la quantité de faisceaux de rayonnement (22) nécessaire à la consolidation de la matière additive (15) dans cette partie. Au cours d'une troisième étape (S3), le procédé consiste à fournir l'ensemble de données de couche modifié en tant qu'ensemble de données de commande pour le dispositif de fabrication additive par couches.
EP18710421.1A 2017-03-24 2018-03-07 Stratégie d'exposition dans des systèmes de fabrication additive (am) à faisceaux multiples Pending EP3579996A1 (fr)

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PCT/EP2018/055626 WO2018172080A1 (fr) 2017-03-24 2018-03-07 Stratégie d'exposition dans des systèmes de fabrication additive (am) à faisceaux multiples

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