EP3585539A1 - Procédé et dispositif pour commander un système d'irradiation pour la fabrication de pièces - Google Patents

Procédé et dispositif pour commander un système d'irradiation pour la fabrication de pièces

Info

Publication number
EP3585539A1
EP3585539A1 EP18700568.1A EP18700568A EP3585539A1 EP 3585539 A1 EP3585539 A1 EP 3585539A1 EP 18700568 A EP18700568 A EP 18700568A EP 3585539 A1 EP3585539 A1 EP 3585539A1
Authority
EP
European Patent Office
Prior art keywords
irradiation
units
area
raw material
material powder
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
EP18700568.1A
Other languages
German (de)
English (en)
Inventor
Andreas Wiesner
Jan Wilkes
Christiane Thiel
Lukas Roesgen
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.)
Nikon SLM Solutions AG
Original Assignee
SLM Solutions Group AG
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
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=60997484&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=EP3585539(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by SLM Solutions Group AG filed Critical SLM Solutions Group AG
Publication of EP3585539A1 publication Critical patent/EP3585539A1/fr
Pending legal-status Critical Current

Links

Classifications

    • 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
    • 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
    • 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
    • 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
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • 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
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • 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
    • B33Y50/02—Data acquisition or data processing for additive manufacturing 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
    • 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
    • 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
    • B22F12/49—Scanners
    • 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
    • B22F2202/00—Treatment under specific physical conditions
    • B22F2202/11—Use of irradiation
    • 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
    • B22F2203/00—Controlling
    • B22F2203/03—Controlling for feed-back
    • 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
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/277—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
    • 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

Definitions

  • the invention relates to a device and a method for controlling a
  • Irradiation system wherein the irradiation system is used for the generative production of three-dimensional workpieces. It includes the
  • Irradiation system at least three irradiation units with mutually overlapping irradiation areas.
  • an initially informal or shape-neutral molding compound for example a raw material powder
  • the irradiation can be effected by means of electromagnetic radiation, for example in the form of laser radiation.
  • the molding compound can initially be present as granules, as a powder or as a liquid molding compound and, as a result of the irradiation, be selectively or, in other words, be solidified in a site-specific manner.
  • the molding compound can be, for example, ceramic, metal or
  • Plastic materials include and also mixtures of materials thereof.
  • a variant of generative layer construction method relates to the so-called powder bed melting, in particular metallic and / or ceramic raw material powder materials are solidified into three-dimensional workpieces.
  • Raw material powder material in the form of a raw material powder layer to be applied to a support and to irradiate selectively and in accordance with the geometry of the currently produced workpiece layer.
  • the laser radiation penetrates into the raw material powder material and solidifies it, for example as a result of heating, which causes melting or sintering. If a workpiece layer is solidified, a new layer of unprocessed raw material powder material is applied to the already produced workpiece layer.
  • known coater arrangements can be used. This is followed by a renewed irradiation of the now uppermost and still unprocessed raw material powder layer. Consequently, the workpiece is successively built up layer by layer, each layer defining a cross-sectional area and / or a contour of the workpiece.
  • solutions are known in which the irradiation of the raw material powder material is performed by an irradiation system comprising a plurality of irradiation units. These can irradiate a single layer of raw material powder together and act in parallel or time offset from one another.
  • Workpiece layer is first evaluated as to which parts of this workpiece layer to be produced extend into the irradiation areas of the individual irradiation units, as well as what proportion in the
  • Irradiating a raw material powder layer which is equivalent to the joint production of a workpiece layer by different irradiation units, can lead to a shortening of the production time compared to using only one irradiation unit.
  • the inventors have recognized that the irradiation by means of different irradiation units can lead to inhomogeneities of the produced workpiece. This may mainly affect the material structure and result in significant quality defects of the workpiece produced.
  • a method for controlling an irradiation system is provided, wherein the irradiation system is used in a device for the generative production of three-dimensional workpieces and at least three
  • Irradiation units comprises.
  • the device can be designed to produce the three-dimensional workpiece in the manner of a selective laser sintering.
  • the irradiation units may be designed to emit an electromagnetic processing beam, for example in the form of a laser beam.
  • an electromagnetic processing beam for example in the form of a laser beam.
  • you may include suitable processing optics and / or beam sources or be connectable to such units.
  • at least two of the irradiation units are connected to a common beam source.
  • the processing beam generated by the beam source can be divided by suitable means and / or deflected to the individual
  • Irradiation units to be performed Suitable means for this purpose are beam splitters and / or mirrors.
  • the processing optics can guide at least one processing beam and / or interact with it in the desired manner. For this you can
  • Objective lenses include, in particular, an f-theta lens.
  • the irradiation units may further comprise deflecting means for directing the emitted processing beams to predetermined areas within a
  • the deflection devices may comprise so-called scanner units, which are preferably adjustable by at least two axes. Additionally or alternatively, the irradiation units or at least their radiation emitting areas may be movable in space. In particular, this may include a relative movement to an irradiation plane so that the irradiation units may face different areas of the irradiation plane.
  • the method comprises the step a) of defining an irradiation area for each of the irradiation units, wherein the irradiation areas each comprise a portion at an irradiation plane which is parallel to a support of the irradiation area
  • the irradiation plane may be a two-dimensional planar plane.
  • the irradiation level can each one currently to be irradiated
  • the irradiation plane may further be arranged opposite to the support and preferably be congruent with a construction surface defined by the support.
  • the construction area can be an area within which a workpiece can be produced. More specifically, the build area may define a maximum manufacturable cross-sectional area of the workpiece.
  • the irradiation regions may comprise an area fraction at the irradiation plane, wherein these surface fractions may also overlap.
  • all irradiation areas overlap one another, at least in the common overlap area, or, in other words, that all irradiation areas overlap one another in the overlap area.
  • the overlap region can thus define an area fraction of the irradiation plane into which all irradiation areas extend.
  • there may also be other overlap areas in which only two of the irradiation areas overlap in the following also:
  • Defining the irradiation areas can be done by setting the
  • Deflection spectrum of the deflection units of the irradiation units and / or the determination of a possible range of motion of the irradiation units take place. This can be done by defining appropriate ranges of values in a controller of the device.
  • a first irradiation unit is assigned a first irradiation area, a second irradiation unit a second irradiation area and a third irradiation unit a third irradiation area. Any further irradiation units may furthermore be assigned a respective further irradiation area.
  • the first to third irradiation areas overlap each other in the overlapping area.
  • the remaining portion of the first irradiation area can be irradiated only by the first irradiation unit
  • the remaining portion of the second irradiation area can be irradiated only by the second irradiation unit
  • Irradiation range can be irradiated only by the third irradiation unit and the remaining portion of any further irradiation areas can only be irradiated by the respectively associated further irradiation units.
  • the method further provides the step b) of irradiating a raw material powder layer arranged on the carrier to produce a workpiece layer.
  • the irradiation can take place via the irradiation units of the irradiation system, whereby depending on the definition of the irradiation areas they can irradiate different but also for example in the overlapping area also common parts of the raw material powder layer.
  • the carrier may be provided in a process chamber of the device. This may be a generally fixed carrier or a
  • shiftable carrier act, in particular in the vertical direction
  • the carrier is lowered with increasing number of the produced workpiece layers and preferably in dependence of this number in the vertical direction.
  • the process chamber can be against the
  • the raw material powder layer may comprise all of the above-explained raw material powder materials and in particular a powder of a metallic alloy.
  • the powder may have any suitable particle size or particle size distribution. A particle size of the powder of ⁇ 100 ⁇ m is preferred.
  • the application of the raw material powder layer on the carrier and / or on a raw material powder layer arranged thereon and already irradiated can be effected via known coater units or powder application apparatus.
  • An example of this can be found in EP 2 818 305 AI.
  • workpiece layer may generally be made from a single layer of raw material powder
  • the workpiece layer ie in particular a cross-section of the workpiece to be produced.
  • the workpiece layer may comprise a contour, for example in FIG Shape of an outer contour or outline of the cross section to be produced.
  • the workpiece layer may comprise an at least partially filled surface, for example a solid or solid
  • a predetermined scanning or irradiation pattern can be used, in which a plurality of scan vectors are defined in a known manner within the irradiation plane in order to enable a substantially planar solidification.
  • Overlap area can be irradiated by the irradiation units that are assigned to the respective irradiation areas.
  • the workpiece layer to be produced can thus be made of the portions irradiated by the irradiation units
  • the method further includes the step c) of arranging another one
  • Raw material powder layers are applied, irradiated and solidified site-specific.
  • the method according to the invention is initially characterized in that at least three irradiation units are provided. In the common overlap region, a plurality of irradiation units is thus available, from which flexible selection can be made.
  • Irradiation ranges at the irradiation level in each case between 0% and up to and including 100%; and / or that the proportion of the overlap area at the irradiation level is between 0% and up to and including 100%.
  • a full-field coverage can also be provided in which the irradiation areas each cover up to approximately 100% of the irradiation level. Consequently, each area of the irradiation level of each of the
  • Irradiation units are irradiated. Furthermore, the overlapping area in this case also occupies about 100% of the irradiation level.
  • the overlapping area and / or that the irradiation areas do not occupy more than about 50% or not more than about 20% of the irradiation level.
  • the irradiation units and / or the centers of the respective irradiation areas span a polygon.
  • the irradiation units and / or the centers of the respective irradiation areas do not lie on a common line.
  • the at least three irradiation units can span a triangle, and a quadrangle in the provision of a fourth irradiation unit.
  • the irradiation system comprises a plurality of groups, each comprising a certain number of irradiation units which define a corresponding polygon (or a polygon). These groups can be arranged in such a way that results in a total of a predetermined pattern of irradiation units. Additionally or alternatively, the
  • Irradiation units may be arranged in rows, wherein immediately adjacent rows are offset from one another in at least two directions (for example along orthogonal X and Y axes of the irradiation plane).
  • the centers of the irradiation areas may be understood to mean a respective geometric center or, in other words, a geometric center.
  • the shape of the irradiation areas may be generally arbitrary and may, for example, have a four-, five-, six-, seven- or octagonal shape.
  • the center can be divided by the diagonal intersection
  • a round shape of the irradiation areas is conceivable. According to a variant, all irradiation areas have the same shape, for example a quadrangular or a hexagonal shape, and / or have the same size.
  • the irradiation areas each comprise at least three
  • Irradiation units overlap in a common overlap area.
  • overlapping areas may exist in which the
  • Irradiation unit several overlapping areas to adjacent
  • Irradiation units and in particular more overlap areas with two other irradiation units can be formed by no more than three different irradiation areas, for example to avoid inaccurate transitions within the workpiece structure produced in this area.
  • the method further comprises a step of selecting at least one to be used for irradiating the overlapping area
  • Irradiation unit before all of the at least three irradiation units are available in the overlapping area in order to irradiate the local portion of the raw material powder layer.
  • at least one, at least two or generally up to n-1 irradiation units can be selected from the totality of the irradiation units, where n indicates the total number of irradiation units.
  • n indicates the total number of irradiation units.
  • Raw material powder layers all irradiation units for irradiating the
  • Overlap area can be selected.
  • a further development provides that the step of selecting before the irradiation of the further workpiece layer is carried out again, that is to say, for example, before the irradiation of the further workpiece layer according to method step c).
  • the step of selecting the irradiation units to be used for the overlapping area is repeated in layers.
  • the selection of the irradiation units can generally take place in accordance with the contour, the irradiation pattern or other characteristics of the currently produced workpiece layer and thus can also be adapted individually in layers. Additionally or alternatively, the selection may be made according to one of the criteria explained below, where all
  • the method may further provide that the selection of the for the
  • this variant provides that the groups of irradiation units defined by the selection between two successive raw material powder layers differ from one another, wherein these groups may also comprise only one irradiation unit. In other words, with respect to successive raw material powder layers between the
  • Overlapping a first and a second irradiation unit can be selected. For irradiating a subsequent second raw material powder layer in the overlapping region, however, only the first, exclusively the second or exclusively the third irradiation unit can be selected, and alternatively the second and the third irradiation unit or the first and the third irradiation unit.
  • the first and the second irradiation unit can be used for
  • the overlap area becomes layer by layer
  • Irradiation units irradiated.
  • the usable irradiation units can be exchanged before each raw material powder layer to be irradiated so that individual influences of individual irradiation units on the workpiece structure are less pronounced, at least in the overlapping area
  • the homogeneity of the workpiece texture and the quality of the workpiece can be improved.
  • Raw material powder layers can be applied, wherein before each irradiation of one of these raw material powder layers, a renewed selection and thus a renewed change can take place from the usable in the overlap irradiation units. It is further understood that according to the invention it may also be provided that such a change of the selected irradiation units does not occur between perform each of the raw material powder layers to be irradiated. Instead, this selection may also be over a predetermined number, for example
  • the method is based on at least two
  • successive raw material powder layer to be irradiated is applied.
  • the number of successive raw material powder layers to be irradiated may also comprise at least 10, at least 50, at least 200 or at least 500. Likewise, it can be provided that with respect to a
  • the present method can be applied to at least 20%, at least 50%, at least 80%, or about 100% of the raw material powder layers to be irradiated as part of a single workpiece manufacturing process.
  • a further embodiment provides that a plurality of irradiation units for irradiating the overlapping area is selected in order to irradiate the overlapping area in parallel or in succession.
  • the manufacturing time of the corresponding workpiece layer can be reduced.
  • the following step is carried out for selecting the irradiation units for the overlapping area:
  • irradiation units for irradiating the overlapping area can be selected.
  • it can be provided not to select an irradiation unit for the irradiation of the overlapping area which is not used further outside the overlapping area for producing the current workpiece layer.
  • in an upstream step it can first be ascertained in which processing areas a currently produced workpiece layer is also outside the overlapping area extends into it.
  • a better transition in the workpiece texture between the overlap area and the adjacent portions of the workpiece layer can be achieved, since a minimum number of irradiation units are used for this purpose.
  • it may further be provided that predominantly or exclusively those irradiation units are selected which produce portions of the workpiece layer which directly adjoin the
  • Workpiece layer extends from the overlap region directly into it. Subsequently, predominantly or exclusively irradiation units can be selected which are assigned to these irradiation areas. Consequently, it can also be provided for the irradiation of the overlapping area not to select any irradiation units which produce portions of the workpiece layer to be produced at any point outside the overlapping area. Instead, it is possible to select those irradiation units which operate in the immediate vicinity or at the transition to the overlap region.
  • a prioritization between these selection criteria can also be undertaken. For example, it may be provided that initially a selection of possible irradiation units takes place taking into account the portions of the workpiece layer to be produced outside the overlapping area, whereupon it is then checked whether these irradiation units can be used in layers in the overlapping area
  • Allow irradiation units If this is not the case, depending on the prioritization, the initially selected irradiation units can nevertheless be continued or this selection is discarded and the
  • Irradiation units are selected solely to achieve the desired layer-by-layer alternation of the irradiation units used.
  • the workpiece layer to be produced does not extend outside of the overlap region. This allows for an improved
  • Workpiece layer can be reduced, since a higher degree of parallelization in the irradiation of the raw material powder layer can be achieved.
  • the definition of the irradiation areas is carried out in such a way that the arrangement of the overlapping area within the irradiation plane between two successive
  • Raw material powder layers changes.
  • the overlap region for irradiating a first raw material powder layer may be arranged in a first position within the irradiation plane and for irradiating a second one
  • Raw material powder layer in a second position which differs from the first position.
  • the overlapping region does not remain in a constant position or arrangement within the irradiation plane. Instead, it can be repositioned for irradiation of a subsequent or even generally before each newly irradiated raw material powder layer. It can thus be achieved that the overlapping area, relative to the workpiece produced, does not maintain a locally constant position but can change its position at least between selected or in all workpiece layers. Any inhomogeneities associated with the irradiation of the overlapping area, such as inaccurate transitions in the workpiece structure between the overlap area and the adjacent irradiation areas, can thus be reduced and / or distributed more uniformly over the entire workpiece.
  • the irradiation areas can be redefined before or parallel to the irradiation of a new raw material powder layer, whereby a repositioning of the overlapping area can also be achieved. This can be done for example by a suitable calculation of a new position and extension of the irradiation areas and / or by reading suitable pre-stored positions from a memory.
  • the overlapping region can thus preferably be at least two angles to each other within each layer within the irradiation plane
  • Directions are shifted, for example along mutually orthogonal axes.
  • This can be a conventional X and Y axis of
  • the shifting can be done randomly or according to a predetermined pattern. For example, the
  • the method may further include methods comprising the steps of:
  • Overlapping but also be positioned in the manner described above within the irradiation level variable and / or the selection of usable irradiation units can be selectively varied.
  • the division areas can, similar to the irradiation areas, the
  • Overlap area and the irradiation level define virtual areas within which the irradiation units can be used.
  • a triangular shaped overlap area can be subdivided into individual triangles form corresponding division regions and are each assigned to one of the irradiation units.
  • a triangular shaped overlap area can be subdivided into individual triangles form corresponding division regions and are each assigned to one of the irradiation units.
  • Irradiation units a square overlap region to be defined, which in turn can be subdivided by respective division regions into individual squares.
  • the position, the size, the number and / or the shape of the division regions can thereby be varied in a targeted manner by changing the division region boundaries between successive raw material powder layers.
  • Irradiation units is assigned between successive
  • Raw material powder layer vary.
  • the irradiation units can carry out different irradiation processes in the overlapping area even with a workpiece layer to be produced the same time, since they are assigned different pitch ranges in layers.
  • the divisional area boundaries may define predetermined areas in which a handover between the irradiation units takes place immediately.
  • irradiation may be in accordance with a predetermined
  • Divisions do not define a narrow range at which such a handover occurs immediately. Instead, it may be provided, for example, that an irradiation unit irradiates along a predetermined path
  • Irradiation vector also continues beyond a dividing range limit, so does not break off the irradiation immediately upon reaching the division region.
  • this irradiation unit does not receive an irradiation along further vectors, which start again only from the point of view of the irradiation unit after the graduation range boundary.
  • the dividing area boundary may specify a range beyond which no new irradiations by the irradiation units can be recorded. This is
  • the change of the division range limits a shifting of an intersection of the
  • Overlap area is assigned, the division area boundaries can intersect at a common point, which corresponds to a geometric center of the overlapping area with the same size of the division areas.
  • Irradiation plane and preferably in at least one of two in an angle to each other extending directions.
  • the directions may be analogous to shifting the entire overlap area about mutually orthogonal axes, for example about the X and Y axes of the
  • the dividing range limits can be automatically adjusted and the size ratios of the division ranges change automatically accordingly.
  • the shifting of the intersection can be done randomly or according to a predetermined pattern, again with a helical shifting over
  • a further embodiment provides that the irradiation system comprises at least one group of at least three irradiation units, and the method further comprises the following steps:
  • irradiation areas per irradiation unit such that their common overlapping area is arranged at least partially within the polygon.
  • a common triangle can be spanned.
  • the overlapping area can be at least partially positioned (for example, in the center).
  • Each irradiation unit can be a rectangular or square
  • each irradiation unit from such a group can have an irradiation area, which can also be combined with at least one irradiation area of a further irradiation unit
  • the invention further relates to a device for producing layers
  • three-dimensional workpieces comprising:
  • an irradiation system having at least three irradiation units
  • Irradiation system is irradiated
  • control unit configured to define an irradiation area for each of the irradiation units, wherein the irradiation areas each comprise a portion of an irradiation plane extending parallel to the support, and wherein the control unit is further adapted to irradiate the irradiation areas define that they overlap in a common overlap area;
  • control unit is further adapted to control the device such that successively arranged on the carrier
  • Raw material powder layers for producing successive workpiece layers can be irradiated by the irradiation system.
  • the apparatus may generally comprise any further features and components for carrying out all of the above-described steps and for achieving all of the effects explained above.
  • the control unit may be designed to carry out all variants with regard to the selection of the irradiation units to be used in the overlapping area, varying the position of the overlapping area in the irradiation plane and defining and / or changing any division areas.
  • the device comprises at least four irradiation units and the irradiation areas are defined such that all irradiation areas of the irradiation units are in one
  • overlap common overlap area This is preferably at least partially within a rectangle spanned by the irradiation units.
  • Figure 1 a view of a device according to the invention
  • FIG. 2 a representation of the irradiation areas of the device from FIG. 1;
  • FIG. 3 shows a representation of possible division regions of the device from FIG.
  • FIG. 1 shows a device 10 which is designed to be
  • the device 10 comprises a process chamber 12.
  • the process chamber 12 is sealable against the ambient atmosphere, so that an inert gas atmosphere can be set therein.
  • a powder application device 14, which is arranged in the process chamber 12, deposits raw material powder layers on a carrier 16.
  • the carrier 16 is adapted to be displaceable in a vertical direction.
  • the device 10 further comprises an irradiation system 20 for selectively and location-specifically directing a plurality of laser beams 24a, b onto the raw material powder layers on the carrier 16. More specifically, the raw material powder material can be produced by means of Irradiation system 20 in accordance with a geometry of a manufactured
  • the irradiation system comprises four irradiation units 22a-d, of which only the front two irradiation units 22a-b can be seen in FIG.
  • the further irradiation units 22c-d are offset in the plane of the page and thus behind the irradiation units 22a-b which can be seen in FIG.
  • Each of the irradiation units 22a-d is coupled to a common laser beam source.
  • the laser beam emitted by this laser beam source may be split and / or deflected by suitable means, such as beam splitters and / or mirrors, to guide the laser beam to the individual irradiation units 22a-d.
  • suitable means such as beam splitters and / or mirrors
  • a suitable laser beam source may be provided in the form of a diode-pumped ytterbium fiber laser having a wavelength of about 1070 to 1080 nm.
  • Each of the irradiation units 22a-d further includes a processing beam optics to interact with the provided laser beam.
  • the processing beam optics each comprise a deflection device in the form of a scanner unit, which can flexibly position the focal point of the laser beam 24a, b emitted in the direction of the carrier 16 within an irradiation plane 28 extending parallel to the carrier 16.
  • the irradiation plane 28 represents a virtual plane which contains a topmost raw material powder layer arranged on the carrier 16 which is currently to be irradiated for producing a workpiece layer. The position of the irradiation plane 28 thus changes relative to the carrier 16 with increasing number of
  • Irradiation level 28 does not change relative to the irradiation units 22a-d, since it is always arranged constant within the process chamber 12.
  • the irradiation of the raw material powder layers by the irradiation system 20 is controlled by a control unit 26.
  • This is further adapted for each of Irradiation units 22a-d to define a likewise virtual irradiation area 18a-d, each extending in the irradiation plane 28 and include a predetermined portion thereof.
  • FIG. 1 again only the irradiation areas 18a-b of the irradiation units 22a-b recognizable there are shown.
  • FIG. 2 shows a plan view of the carrier 16 and the irradiation plane 28 from the perspective of the irradiation system 20. It can be seen that the irradiation plane 28 is square-shaped and therefore comprises four equal-sized quadrants I-IV. Approximately in the center of each of these quadrants I-IV is one of each
  • Irradiation units 22a-d arranged.
  • the control unit 26 defines for each of the irradiation units 22a-d a separate irradiation area 30a-d.
  • Irradiation areas 30a-d are in the case shown for each of the
  • Irradiation units 22a-d are the same size and rectangular. Further, they are defined such that the irradiation units 22a-d are disposed slightly eccentrically within the irradiation areas 30a-d.
  • Irradiation area 30d which is shown in the manner of a die.
  • the outlines of the further irradiation areas 30b, c are in principle chosen to be the same. Consequently, it can be seen that the irradiation areas 30a-d overlap several times, whereby an overall cross-shaped overlapping zone 32 is defined within the irradiation plane 28.
  • the overlapping zone 32 has a common
  • Overlap area 34 in which all irradiation areas 30a-d overlap and overlap each other. Starting from this presently square overlap region 34, further cross-shaped extend
  • Irradiation areas 30a-d overlap each other.
  • the irradiation units 22a-d are arranged in such a way that together they form a polygon in the form of a rectangle
  • FIG. 2 also shows an outline of a workpiece layer 38 to be produced.
  • the outer contour is produced by site-specific irradiation and solidification of the currently top raw material powder layer.
  • the workpiece cross-sectional area bordered by the outline is substantially completely solidified and thus filled or, in other words, solid. This can be followed by means of known irradiation patterns, comprising, for example, a plurality of scanning vectors running parallel to each other.
  • the workpiece layer 38 to be produced has different proportions with which it can be divided into the individual components
  • Irradiation areas 30a-d but also in the overlap region 34 and the secondary overlap regions 36 extends.
  • the irradiation units 20a-d In order to produce the workpiece layer, the irradiation units 20a-d must thus be controlled in a coordinated manner by the control unit 26 in order to be able to produce a portion of the workpiece layer 38 associated therewith.
  • Workpiece layer 38 extends exclusively in one of the irradiation areas 30a-d and outside of the overlapping zone 32, this portion can be solidified directly by the respective associated irradiation unit 22a-d.
  • the control unit 26 implementing the method according to the invention provides that those actually used for the irradiation
  • Irradiation units 20a-d are selected specifically.
  • a plurality of double arrows 1-4 are shown, each of which extends between two of the irradiation regions 30a-d and in each case through one of the secondary overlapping regions 36. If a laser beam 24a-b is to be guided along one of these double arrows 1-4 in order to produce a desired workpiece layer, the control unit 26 decides which of the irradiation units 22a-d within the common secondary overlap region 36 should undertake the irradiation of the raw material powder layer. Additionally or alternatively, however, it may also be provided that both of the irradiation units 22a-d, which a
  • Control unit 26 pretend that the irradiation unit 22b continues the irradiation, until in Figure 2, the upper limit of
  • FIG. 2 two further double arrows 5-6 are shown in FIG. 2, which extend diagonally within the irradiation plane 28 and in particular through the common overlap region 34. Since all the irradiation areas 30a-d overlap within this overlap area 34, the control unit in this area can select between all of the irradiation units 22a-d to irradiate the portion of the raw material powder layer enclosed thereby.
  • Irradiation unit 22a takes place until the common overlap region 34 is reached. There, the control unit 26 then specify which of the
  • Irradiation units 22a-d for the irradiation of the raw material powder layer should be selected in this area or whether for this purpose several or all irradiation units 22a-d should cooperate. After passing through the common overlap region 34, the irradiation along the arrow 5 is again continued with the upper irradiation units 22d in FIG. 2 on the right.
  • control unit 26 can only those irradiation units 22a-d for irradiating the overlapping area 34.
  • Overlap area can be used to perform the desired irradiation.
  • the further irradiation units 22b, c which are not used for irradiation outside the common overlap area 34 can not be deliberately selected in order to minimize the risk of inaccurate transitions within the workpiece structure by frequently changing the irradiation units 22a-d.
  • One aim of the embodiment shown is to distinguish from the multiple overlaps of the irradiation areas 30a-d as well as the ones described
  • the inventors have recognized that a homogeneity improvement can be achieved, for example, if the irradiation conditions are selected to be as variable as possible in order not to produce the same inaccuracies in each workpiece layer at the same position.
  • this can be achieved by selecting each individual raw material powder layer to be irradiated, which of the irradiation units 22a-d actually is in the common
  • Overlap area 34 and / or the secondary overlap areas 36 are used. Care is also taken to ensure that this selection is included in
  • Irradiation conditions within the overlap zone 32 thus be changed in layers.
  • Irradiation level 28 to change layer by layer The overlapping region 34 and in particular a geometric center thereof is thereby within the
  • FIG. 3 shows a further variant for irradiating the raw material powder layer, which can be carried out with the present embodiment. It can be seen again the irradiation plane 28 and the cross-shaped arranged therein
  • Overlap zone 32 With the exception of the subdivision of the overlapping zone 32 explained below, this example is designed analogously to that of FIG. For reasons of clarity, therefore, not all reference signs are also entered again in FIG.
  • FIG. 3 Various possibilities are shown in FIG. 3 as to how the overlapping zone 32 can be subdivided in a different manner by varying dividing range boundaries between successive raw material powder layers to be irradiated. A current position of the dividing range boundaries is shown in bold and dashed lines in FIG.
  • PSlx-PS4x PSly-PS4y are composable. These division regions can each be assigned to one of the irradiation units 22a-d again.
  • Division regions of the overlapping zone 32 can take place in particular with regard to the common overlapping region 34. There you can see that the
  • Division boundaries are intersected at a common point P. Accordingly, the common overlapping region 34 is likewise divided into four portions of different sizes, each of which forms a division region T1-4 of the common overlapping zone 34. Each of these division areas Tl-4 is one of
  • Irradiation unit 22c of the largest division area Tl is assigned and the lower right irradiation units 22b of the smallest division area T3.
  • Irradiation is continued directly by an irradiation unit 22a-d associated with an adjacent division area).
  • the dividing area boundaries may also define only a general area that may also be temporarily exceeded when irradiated along a predetermined vector by the irradiation units 22a-d.
  • irradiation along a new irradiation vector which begins only after the division irradiation boundary from the point of view of the respective irradiation unit 22a-d, can not be made possible.
  • Raw material powder layers provides the embodiment shown the possibility to vary the position of the intersection P of the division area boundaries within the common overlap region 34. In concrete terms, this one can
  • Intersection P are moved along at least one of the X-Y axes. Analogous to the above-discussed shifting the entire common
  • the intersection point P can be moved randomly or according to a predetermined pattern. As a consequence of shifting the intersection point P, the sizes of the division regions Tl-4 also change.
  • one and the same portion of the common overlap region 34 can be dependent on a position of the intersection point P and over several
  • the division area boundaries between successive raw material powder layers can be changed in each case. This can be done in particular such that the subdividing areas N1, N2 defined by the portions PSlx-PS4x between the consecutive Differentiate raw material powder layer from each other. If, for example, the irradiation of the current raw material powder layer is completed in the variant according to FIG. 3, the control unit 26 can shift the graduation range boundaries shown in dashed lines such that the upper secondary overlap region 36 is divided in the middle. Consequently, the irradiation unit 22d would have a secondary division area N1 comprising the portions PS3x-PS4x and the irradiation unit 22c a secondary division area N2 comprising the portions PSlx-PS2x.
  • FIGS. 4 and 5 show further possibilities for arranging a plurality of irradiation units, which are shown in a cross shape and always provided with the same reference numeral 50. For reasons of clarity, however, not all irradiation units are provided with this reference symbol.
  • the views of FIGS. 4 and 5 likewise represent a plan view of an irradiation plane 28 analogously to FIGS. 2 and 3.
  • the arrangements of the irradiation units 50 shown in FIGS. 4 and 5 can in principle be used in the device 10 explained above. In the following, therefore, the same reference numerals are used for similar or equivalent features.
  • FIG. 4 and 5 show further possibilities for arranging a plurality of irradiation units, which are shown in a cross shape and always provided with the same reference numeral 50. For reasons of clarity, however, not all irradiation units are provided with this reference symbol.
  • the views of FIGS. 4 and 5 likewise represent a plan view of an irradiation plane 28 analogously to FIGS. 2
  • FIG. 4 shows that a total of nine irradiation units 50 are provided, which are offset relative to one another along the YX axes within the irradiation plane 28.
  • three irradiation units 50 aligned in the Y direction are shown, three of them being provided in total and spaced apart along the X axis.
  • a middle row is offset from the outer rows in the Y direction.
  • a group of three irradiation units 50 is formed, the square irradiation areas 52 of which overlap one another in a common overlapping area 34.
  • not all irradiation and overlapping regions 34, 52 in FIGS. 4 and 5 are provided with a corresponding reference numeral.
  • Irradiation units 50 within a group thereby span a schematically indicated virtual triangle, in which the common overlap region 34 is arranged almost completely.
  • Irradiation unit 50 are assigned to a plurality of groups of irradiation units 50, with which it forms a common overlap region 34. This applies, for example, to the irradiation unit 50 marked by the arrow Z in FIG. 4, which is assigned to both of the triangular-shaped groups shown in FIG.
  • the irradiation units 50 in FIG. 4 are arranged relative to one another in such a way that their irradiation areas 52 form at least two common overlap areas 34, each with two further irradiation units 50.
  • the irradiation units 50 each have a hexagonal or, in other words, a honeycomb irradiation area 52.
  • the irradiation units 50 are in turn arranged such that in each case groups of three irradiation units 50 are formed, which together form a triangle which encloses a common overlap region 34.
  • each irradiation unit 50 interacts with a plurality of adjacent irradiation units 50 and thus also several common overlap regions 34 and / or
  • Overlap areas 36 defined. In both FIG. 4 and FIG. 5, however, no overlapping regions 34 are formed by more than three different irradiation regions 52, which still results in precise transitions in FIG

Abstract

L'invention concerne un procédé pour commander un système d'irradiation (20), le système d'irradiation (20) étant utilisé dans un dispositif (10) pour la fabrication additive de pièces tridimensionnelles et comprenant au moins trois unités d'irradiation (22a-d, 50), le procédé comprenant les étapes suivantes: a) définition d'une zone d'irradiation (30a-d) pour chacune des unités d'irradiation (22a-d, 50), les zones d'irradiation (30a-d) comprenant à chaque fois une partie d'un plan d'irradiation (28) qui s'étend parallèlement à un support (16) du dispositif (10) et les zones d'irradiation (30a-d) étant définies de manière telle qu'elles se chevauchent dans une zone de chevauchement (34) commune ; b) irradiation d'une couche de poudre de matière première disposée sur le support (16) pour la fabrication d'une couche de la pièce ; c) disposition d'une autre couche de poudre de matière première sur la couche de poudre de matière première déjà irradiée pour la fabrication d'une autre couche de la pièce. d) L'invention concerne en outre un dispositif pour la réalisation de ce procédé.
EP18700568.1A 2017-02-22 2018-01-15 Procédé et dispositif pour commander un système d'irradiation pour la fabrication de pièces Pending EP3585539A1 (fr)

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DE102017202843.2A DE102017202843B3 (de) 2017-02-22 2017-02-22 Verfahren und Vorrichtung zum Steuern eines Bestrahlungssystems zur Werkstückherstellung
PCT/EP2018/050843 WO2018153573A1 (fr) 2017-02-22 2018-01-15 Procédé et dispositif pour commander un système d'irradiation pour la fabrication de pièces

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JP (1) JP6898459B2 (fr)
CN (1) CN110475633B (fr)
AU (1) AU2018226021B2 (fr)
BR (1) BR112019017273B1 (fr)
CA (1) CA3053691C (fr)
DE (1) DE102017202843B3 (fr)
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JP6898459B2 (ja) 2021-07-07
US20190375012A1 (en) 2019-12-12
CA3053691C (fr) 2021-08-24
AU2018226021A1 (en) 2019-09-05
CA3053691A1 (fr) 2018-08-30
CN110475633B (zh) 2022-02-18
BR112019017273B1 (pt) 2023-02-07
DE102017202843B3 (de) 2018-07-19
CN110475633A (zh) 2019-11-19
WO2018153573A1 (fr) 2018-08-30
US11639028B2 (en) 2023-05-02
US20230226753A1 (en) 2023-07-20
RU2737286C1 (ru) 2020-11-26
BR112019017273A2 (pt) 2020-04-14
AU2018226021B2 (en) 2020-05-28
JP2020511595A (ja) 2020-04-16

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Inventor name: ROESGEN, LUKAS

Inventor name: THIEL, CHRISTIANE

Inventor name: WILKES, JAN

Inventor name: WIESNER, ANDREAS