EP3710183A1 - Tri de bandes d'irradiation - Google Patents

Tri de bandes d'irradiation

Info

Publication number
EP3710183A1
EP3710183A1 EP18800160.6A EP18800160A EP3710183A1 EP 3710183 A1 EP3710183 A1 EP 3710183A1 EP 18800160 A EP18800160 A EP 18800160A EP 3710183 A1 EP3710183 A1 EP 3710183A1
Authority
EP
European Patent Office
Prior art keywords
irradiation
layer
cross
component
sectional area
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
EP18800160.6A
Other languages
German (de)
English (en)
Inventor
Sebastian Edelhäuser
Martin Leuterer
Michael GÖTH
Markus Frohnmaier
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 EP3710183A1 publication Critical patent/EP3710183A1/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
    • B22F10/20—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
    • B22F12/17—Auxiliary heating means to heat the build chamber or platform
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/295—Heating elements
    • 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
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • 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
    • G05B2219/35—Nc in input of data, input till input file format
    • G05B2219/35028—Adapt design as function of manufacturing merits, features, for manufacturing, DFM
    • 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
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the invention relates to a method and a device for generating control data for controlling an apparatus for additive production and to a correspondingly adapted manufacturing method for the additive production of at least one component layer of a component, in which a layer of a building material is introduced into a process space and the build-up material of the layer is selectively solidified by irradiation of at least a portion of the layer by means of an irradiation unit.
  • the invention further relates to a control device for a device for the additive production of a component layer of a component and to a device with such a control device.
  • additive manufacturing processes are becoming more and more relevant. This relates in particular to the production of such manufacturing products, which are characterized by a high degree of geometric complexity.
  • Additive manufacturing processes are generally to be understood as those processes in which components or production products are produced directly from computer-based data models, for example digital 3D design data, from shapeless construction materials.
  • 3D printing is often used as a synonym for additive manufacturing; the production of models, samples and prototypes with additive manufacturing processes is often referred to as “rapid prototyping” and the manufacture of tools as “rapid tooling " designated.
  • the structure of a component is predominantly, but not necessarily, in layers, using both solid, but also pasty or liquid materials with different physical and chemical properties are used.
  • An essential feature of additive manufacturing is the selective, ie spatially limited solidification of a layer of building material.
  • a preferred solidification method is the irradiation of the building material with radiant energy, for example in the form of electromagnetic radiation, in particular light and / or heat radiation. Alternatively, the irradiation can also be carried out with particle radiation, such as, for example, electron radiation.
  • radiant energy for example in the form of electromagnetic radiation, in particular light and / or heat radiation.
  • particle radiation such as, for example, electron radiation.
  • Two commercially significant processes involving solidification of the building material by irradiation with radiant energy are "Selective Laser Sintering" (DMLS) and “Selective Laser Melting” (SLM). There are repeated thin layers a mostly powdered building material in a process space of a device for additive manufacturing of a component applied to each other, each layer is irradiated limited space.
  • the irradiation takes place in such a way that only those parts of the layer which are to become part of a manufactured product are irradiated. Due to the locally introduced radiation energy, the powder grains of the building material are partially or completely melted. They connect with each other, so that after cooling, a solid is present.
  • the area of the layer in which the energy input into the building material currently takes place is called the irradiation point.
  • one or more high-energy beams for example by means of a suitable deflection device, of an irradiation unit are directed to a specific location of the surface of the layer, this location corresponding to the irradiation point.
  • the high-energy beam or the irradiation point is guided over the surface of the layer along a number of scan lines.
  • a scan line thus corresponds to the path or the course which the irradiation point travels on the surface of the layer, wherein the layer is solidified in the region of the scan line.
  • the arrangement of the scan lines can take place according to one of the irradiation patterns explained below.
  • the surface of the layer is subdivided into a number of virtual irradiation strips, for example by means of a suitable arithmetic device, wherein a number of scan lines are arranged within an irradiation strip.
  • a number of scan lines are arranged within an irradiation strip.
  • the "cross-sectional area of the component layer” or “component cross-sectional area” is to be understood as the area of the layer of the building material which is solidified to produce the component in this layer ,
  • the component cross-sectional area corresponds schematically to the (formed by the individual powder grains) surface of the component layer to be solidified.
  • the "component layer” is understood to mean a three-dimensional body which is defined by the cross-sectional area and the corresponding depth or thickness of the component layer.
  • a finished manufactured component consists of the sum of its component layers or a number of component layers.
  • a "layer” is understood to mean the build-up material applied in layers in the construction field of the device.
  • solidification layer regions In a layer of the building material, therefore, several separate, d. H. be arranged unbound, to be consolidated layer areas.
  • the solidification layer regions may belong to a single component or to a plurality of separate components. In the former case, the entirety of the solidification layer regions would correspond to the surface cross-section of the component cross-sectional area of a component to be consolidated.
  • individual solidification layer regions could be arranged, which belong to five separate components to be produced in the same manufacturing process.
  • each of the components to be fabricated in this layer 20 could include individual solidification layer regions.
  • the invention is not limited thereto. Rather, the method according to the invention for the analog production of a number of separate component layers, ie. H. suitable for the production of different components in a common additive manufacturing process.
  • the irradiation strips which are arranged for selective irradiation of the surface of the layer virtually on the same, need not necessarily be parallel to one another in the context of the invention.
  • the irradiation strips can also run approximately parallel to one another, so that the outer edges or outer boundaries of at least two irradiation strips form an angle to one another, which can be up to 5 °, for example.
  • the two outer edges of a virtual irradiation strip run predominantly in a straight line.
  • an irradiation strip, at least in one Partial area also include a curvature. Below and within the scope of the invention, for the sake of simplicity, a number of straight-line and substantially parallel virtual irradiation strips are assumed, the invention not being restricted thereto.
  • the irradiation of the layer can be done on the model of a chess board. This means that the surface of the layer is virtually subdivided into a number of partial areas, the irradiation initially taking place only in those partial areas of the layer which are equivalent to a specific "color" of the chess board, so that respectively adjacent partial areas of the layer first be skipped by the irradiation.
  • a third irradiation pattern is based on the checkerboard pattern explained above, where irradiation of the subregions occurs here arbitrarily.
  • the subregions of the layer are thus in a random sequence, i. H. without a recurring, solid pattern irradiated ("island pattern"). It also applies to the two last-mentioned irradiation patterns that the virtually arranged subregions are solidified only in areas in which there is an overlap with the component cross-sectional area to be solidified.
  • the irradiation patterns described above are all suitable for selectively consolidating a layer of a building material and thus for producing a component in an additive manufacturing process. However, it has been shown that the irradiation pattern exerts an influence on the quality of the finished component.
  • the stripwise irradiation of the layer along irradiation strips has proved to be particularly advantageous.
  • a virtual irradiation strip has only a slight overlap with the component cross-sectional area to be solidified.
  • the entire irradiation strip has to be separately activated and scanned by the irradiation unit.
  • An inventive method relates to the generation of control data for controlling a device for the additive production of at least one component layer of at least one component in an additive manufacturing process.
  • a layer of building material is introduced into a process space of the device, wherein the build-up material of the layer is selectively solidified by irradiation of at least a portion of the layer by means of an irradiation unit.
  • control data or process control data is understood here as a sequence of instructions or commands in order to make the device for additive manufacturing (with its various components), as explained in more detail later induce a number of layers of building material in to introduce a process space of the device successively and to scan at least those areas which are to be solidified to produce a component layer with radiation energy for selective solidification.
  • the control data are based on a computer-based model of the at least one component to be produced, preferably a CAD model.
  • a thickness of the building material can be defined for each individual layer and, in addition, the areas of the layer can be determined at which a solidification of the layer is to take place by means of an energy supply.
  • control data can also include all the data required for controlling the irradiation unit, whereby inter alia the intensity and / or energy density of the radiation energy introduced into the layer, a movement speed of the irradiation site and / or an irradiation pattern can be determined.
  • the irradiation pattern in particular the virtual arrangement of irradiation strips on the surface of the layer as well as the length of the individual scan lines within the irradiation strips can be determined by the control data.
  • the control data can be used to determine a sequence of solidification of a plurality of partial regions of a layer, for example if a layer comprises a plurality of separate solidification layer regions.
  • an advantageous irradiation strategy of the individual layers can be taken into account in the control data, as will be explained in detail later at a later point in time.
  • control data may comprise all the information needed to control an additive manufacturing device in order to control the device for producing at least one component layer of at least one component in an additive manufacturing process.
  • the control data which are collectively referred to as a control data set, may alternatively or additionally also include information for the production of further objects in the additive manufacturing process, for example support structures or the like.
  • control data are created in such a way that the device is controlled so that the build-up material of each layer is selectively solidified by irradiation of at least a portion of the layer by means of an irradiation unit.
  • the control of the device by the control data is carried out so that for solidification an irradiation site is moved by the irradiation unit along a number of scan lines of one or more irradiation strips.
  • Each of these irradiation strips has a predefined maximum width, wherein the scan lines run within the maximum width of the irradiation strip and essentially transversely to a feed direction of a solidification region along the irradiation strip.
  • the control data are generated such that at least two irradiation strips of a layer are assigned a different maximum width as a function of a control parameter, in particular of a component geometry.
  • an irradiation point is to be understood as meaning a defined area or locally limited location at which the energy input into the layer of the building material takes place through the irradiation unit.
  • the irradiation point thus corresponds to the point of solidification of the building material and can thus also be referred to as "solidification point” or “solidification point”.
  • the energy input preferably takes place by means of at least one high-energy beam, for example a laser beam, which is controlled by the irradiation unit in accordance with the control data and directed onto the surface of the layer by means of a suitable deflection device.
  • the irradiation point is moved in accordance with the control data along a number of scan lines which are arranged within an irradiation strip, such as hatching, for which reason the scan lines are also referred to as "hatching lines".
  • scan line or “hatching line”, unless explicitly stated otherwise, means the movement of the irradiation point on the surface of the layer of the building material.
  • the scan line thus corresponds to the path or the course which the irradiation point travels on the surface of the layer, the solidification of the build-up material of the layer taking place in the region of the scan lines.
  • the scan lines are arranged within virtual irradiation strips, so that the irradiation or the solidification of the layer takes place strip-like along a number of virgin irradiation strips.
  • a virtual irradiation strip is irradiated only in those areas in which an overlap of the virtual irradiation strip with the component cross-sectional area to be solidified is present. lies. This means that an "actually solidified radiation strip" consists of the sum of its scan lines or exists only in the form of its scan lines.
  • both the scan lines and the irradiation strips are initially arranged virtually on the layer or on a construction field of the device.
  • the irradiation strips or the scan lines can be calculated for this purpose by means of a suitable computing device.
  • an irradiation strip should always be understood to mean a "virtual" irradiation strip.
  • the information relating to the arrangement, the design, etc. of the virtual irradiation strips or scan lines are thus encompassed by the control data.
  • the actual, actual irradiation of the layer e.g. in the context of a production method according to the invention, on the basis of the thus generated control data, d. H. according to the virtually arranged scan lines or irradiation strips.
  • a solidification area is therefore to be understood as the area of the layer in which the actual hardening of the building material takes place.
  • a solidification region often comprises one or a portion of a currently irradiated scan line.
  • the "advancing direction" of the solidification or of the solidification region is understood to be the direction of propagation of the solidification along the course of the actually solidified irradiation strip during the production of the component layer.
  • the advancement of the solidification takes place in a direction along the longitudinal extent of the irradiation strip.
  • the feed direction describes the propagation or advancement of solidification on a macro-level, ie. H. at the level of the whole irradiation strip.
  • the movement of the irradiation site refers to a micro-level of solidification, ie to the movement of the irradiation site along the individual scan lines within an irradiation strip.
  • the movement Movement of the irradiation site along the scan lines on a micro level the advancement of solidification along the irradiation strip on a macro level.
  • the control data are preferably generated in such a way that the scan lines of a radiation strip run essentially transversely to the feed direction of the solidification region, wherein the scan lines are preferably arranged with a deviation of at most 30 ° relative to the feed direction.
  • the scan lines of an irradiation strip are arranged at right angles to the feed direction of the solidification region of the irradiation strip.
  • the scan lines are preferably arranged substantially parallel to one another, the invention not being restricted thereto.
  • the scan lines of an irradiation strip run alternately or in opposite directions.
  • the scan lines may also be arranged rectified and / or form a regular pattern or a number of different patterns within the irradiation strip.
  • the running of the scan lines within the maximum width of an irradiation strip thus means that the scan lines do not exceed the outer boundaries or outer edges of a radiation strip.
  • the maximum width of a radiation strip at a given angle of the scan lines to the feed direction of the solidification region is defined by the maximum possible length of the scan lines in this radiation strip.
  • the sharp boundary of the scan lines at the outer edges of an irradiation strip is defined by the control data, i. H.
  • the irradiation point is not moved in a controlled manner beyond points or lines which mark the outer edges or the outer limits of the irradiation strip in the control data. Due to factors such. As the inevitable heat propagation in the material but it may happen during the manufacturing process in practice that the effective range of the high energy beam minimally exceeds the outer limits of an irradiation strip.
  • the control data are preferably generated in such a way that the virtual irradiation strips substantially completely cover the surface of the layer or a construction field of an apparatus for additive production.
  • a number of virtual radiation strips are arranged locally in a subregion of the layer, wherein at least the regions of the layer to be consolidated or the component cross-sectional area of the virtual irradiation strips are included.
  • control data are preferably generated such that each irradiation strip of a layer has a predetermined "maximum width".
  • the maximum width corresponds to the largest extent of an irradiation strip in a direction transverse to its longitudinal extent (or transversely to the feed direction).
  • the maximum width is assigned individually or separately for each irradiation strip of a layer, with a new allocation of the maximum width of the irradiation strips taking place in each layer of the building material.
  • the allocation of the maximum width of an irradiation strip takes place as a function of a control parameter, in particular of a component geometry, for example by means of a computing device.
  • the maximum width of the virtual irradiation strips which are arranged to consolidate a component layer on the component cross-sectional area, is heterogeneous within a component layer, that is, internal to the layer, and thus not uniform.
  • the design or geometry of the component cross-sectional area and / or the position of the component cross-sectional area within the construction field as well as comparable parameters can serve as control parameters by means of which the maximum width is assigned.
  • the configuration of at least one subregion of the component layer to be consolidated can serve as a control parameter.
  • a layer of a building material may comprise a number of consolidation layer areas of one or more separate components to be produced.
  • the control data can thus be generated so that the device, if it is driven in accordance with the control data, is designed to produce time-overlapping production of a number of separate components in a common production process.
  • the layer may also comprise further regions to be solidified, for example regions of structures that support and / or encase a component and / or structure a structural volume in a specific manner.
  • the assignment of the maximum width of the irradiation strips can be determined on the basis of the embodiment of a subarea, preferably of the entirety of the processes that are involved in an additive manufacturing process. subregions or hardening layer areas of a layer.
  • the term "component layer” is therefore to be understood as meaning the entirety of regions of a layer to be consolidated.
  • the assigned maximum width of a virtual irradiation strip and the actually solidified width of an irradiation strip can be different, at least in sections. This means that the scan lines, at least in sections, are arranged with a smaller than the largest possible length in the irradiation strip.
  • a preferred method for generating control data according to the invention could comprise, for example, the following process steps:
  • model data could be read from a memory or accepted via a network.
  • the model data for solidification of a layer could be read in at once or in sections, z. For example, these can be read in as required, in particular during the production process of a solidification layer area, so that there is a greater time interval between the access operations to parts of the model data.
  • the model data could include basic design parameters of the component layer to be fabricated, for example, information regarding the configuration or geometry of at least one solidification layer region, the location and arrangement of a number of solidification layer regions in a layer, the location and arrangement of a number of virtual irradiation strips, such as as a series of coordinate points in a two-dimensional (layer-related) or three-dimensional (based on a volume of construction) coordinate system can be present.
  • at least one data model of a region of the layer of the building material selectively to be consolidated for producing at least one region of the at least one component layer could then be generated, wherein preferably the acquired model data are modified so as to control the device later Realize the inventively desired way to ren.
  • the device for additive manufacturing is controlled in such a way that, for solidification, an irradiation point is moved through the irradiation unit along a number of scan lines of one or more irradiation strips, wherein each irradiation strip has a predetermined maximum width and wherein the scan lines within the Maximum width of the irradiation strip and extend substantially transversely to a feed direction of a solidification region along the irradiation strip.
  • the desired control data could then finally be generated on the basis of the at least one data model generated in the second step for generating a control data record for the additive manufacturing apparatus.
  • the virtual irradiation strip pattern ie the entirety of the irradiation strips required for solidification of at least a subregion of the layer, to be specific, in particular as accurate as possible the configuration of the subregion of the layer to be consolidated is adapted.
  • this increases the overlap area of each virtual irradiation strip with the component cross-sectional area, so that during irradiation, each irradiation strip of the layer is irradiated substantially completely, ie in accordance with its assigned maximum width.
  • a control data generation device for generating control data for a device for the additive production of at least one component layer of at least one component in an additive manufacturing process in which at least one layer of a build material is introduced into a process space and the build-up material of the layer by irradiation is selectively solidified by at least a portion of the layer by means of an irradiation unit, is designed to generate control data, so that the device for additive manufacturing using the control data is controlled so that for solidification an irradiation point through the irradiation unit along a number is moved by scanning lines of one or more irradiation strips.
  • each irradiation strip has a predefined maximum width, wherein the scan lines extend within the maximum width of the irradiation strip and essentially transversely to a feed direction of a solidification region along the irradiation strip. At least two irradiation strips of a layer are assigned a different maximum width as a function of a control parameter, in particular of a component geometry.
  • Such an apparatus for generating control data for an apparatus for additive manufacturing could, for example, comprise the following features: A data access unit for accessing computer-based model data of at least one area of the at least one component layer to be produced and a data model generation unit.
  • the latter is designed to generate at least one data model of a region of the layer of the building material to be selectively consolidated for producing at least one region of the at least one component layer to be produced, for example, as mentioned, by suitable modification of the adopted model data
  • Data model specifies that the device for additive production is controlled in the manner defined above.
  • the device for generating control data could comprise a control data provision unit which is designed to provide control data or a control data record for the device for additive manufacturing, on the basis of the at least one data model generated by the data model generation unit .
  • the control data providing unit could comprise a suitable data interface, in particular in order to enable transmission of data or the data model between the control data generation device and another device, for example a data processing device.
  • the provision of the data model generated in the second step for the generation of the control data record can, as explained above, be carried out by the control data provision unit, by providing these, for.
  • the generated data model (with the radiation strips or strip widths defined according to the invention) is integrated into an expanded control data record for the device for additive production.
  • Such an extended control data set could already contain further control data which the device for additive manufacturing of a component layer requires, such as control data for controlling a radiation source, a mirror system for aligning or moving a high energy beam of the radiation source, global or local heating of the construction field
  • control data for controlling a radiation source such as control data for controlling a radiation source, a mirror system for aligning or moving a high energy beam of the radiation source, global or local heating of the construction field
  • the data model generated in the second step could be supplemented or modified to allow a particularly advantageous irradiation strategy of the component layer, for example by suitable starting or end points of the irradiation of at least a portion of the component layer to be produced be determined. More detailed examples will be given later.
  • provision here also means that the data model is forwarded to a data processing device which integrates the data model into such an extended control data record, or a direct forwarding to an apparatus for additive manufacturing.
  • a control data generation device can be realized for example in the form of hardware and / or software components in a computing device.
  • This computing device can, for. B. part of the device for additive manufacturing itself, as part of a control device o. ⁇ ., As will be explained later. But it is also conceivable that the control data generating device is designed independently, that is spatially separated from the device for additive manufacturing.
  • a control device for a device for the additive fabrication of at least one component layer of one or more components requires a computing device, for example a number of microprocessors or data processors or the like, in order to match an irradiation unit of the device according to process control data or according to a To control the irradiation strategy such that the irradiation point of the irradiation unit is moved along a number of scan lines of one or more irradiation strips, wherein each irradiation strip has a predetermined maximum width and wherein the scan lines are within the maximum width of the irradiation strip and substantially transverse to a feed direction of a solidification Run along the irradiation strip, and wherein at least two irradiation strips of a layer depending on a control parameter, in
  • control device may include a memory for an irradiation control protocol with irradiation control data, a control unit, for example a microprocessor or the like, to calculate and process an irradiation control protocol on the basis of process control data, and corresponding suitable interfaces to the components of the irradiation unit to control, for example, the radiation source, the mirror system and locally movable in the process space Hilfsvor- directions or other components according to the irradiation control protocol, ie to feed the components with suitable control signals.
  • a control device can also have all the known customary components which hitherto are present in such control devices for devices for the additive production of production products.
  • control device can therefore, as mentioned, be realized with the aid of a computing device with suitable software or software program parts.
  • a largely software-based implementation has the advantage that even previously used control devices can be retrofitted in a simple manner by a software or firmware update in order to work in the manner according to the invention.
  • the problem is also solved by a corresponding computer program product with a computer program which is stored directly in a memory device of a control unit.
  • erffleerzeugungsvorraum and / or a control device of a device for additive manufacturing of a device layer of a component is loadable with program sections to perform all steps of the inventive method for generating control data when the computer program is executed in the control data generating device and / or control device.
  • Such a computer program product in addition to the computer program optionally additional components such.
  • additional components such as a documentation and / or additional components, including hardware components such.
  • B. hardware keys (dongles, etc.) for using the software include.
  • a computer-readable medium for example a memory stick, a hard disk or another transportable or permanently installed data carrier, on which the data from a computing device of the control data generating device and / or the STEU - Edible and executable program sections of the computer program are stored.
  • a layer of a buildup material is introduced into a process space, wherein the build-up material of the layer is selectively solidified by irradiation of at least a portion of the layer by means of an irradiation unit ,
  • an irradiation site is moved by the irradiation unit along a number of scan lines of one or more irradiation strips, wherein each irradiation strip has a predetermined maximum width and wherein the scan lines are within the maximum width of the irradiation strip and substantially transverse to a feed direction of a solidification region along the irradiation strip run.
  • At least two irradiation strips of a layer are assigned a different maximum width as a function of a control parameter, in particular of a component geometry.
  • the device for additive production can be controlled by a control data set which has been generated according to the inventive method described above for generating control data.
  • a control data generation device is implemented in the form of hardware and / or software components in a computing device, wherein the computing device is part of a control device of the additive manufacturing device itself. If In the following, therefore, it is said that the control data are generated by the computing device, this means, of course, that the control data is generated by the control data generation device as part of the computing device.
  • a device according to the invention for the additive production of at least one component layer of one or more components has a previously described control device.
  • such a manufacturing device should also comprise all further customary components of such a device, such as a process chamber or a process chamber with a coating device in which the build-up material can be introduced in a suitable manner, for example in layers, and a suitable one Irradiation unit for selectively solidifying the building material in the process space so as to produce the finished product as a solid object.
  • the manufacturing device can comprise a number of auxiliary devices that can be moved locally in the process space, for example a local heating device.
  • the control data are preferably generated in such a way that the movement of the irradiation point in an additive manufacturing process is adapted, at least in sections, to the advance of an auxiliary device that can be moved locally in the process space.
  • the assignment of the different irradiation strip maximum widths can be determined inter alia by this feed, or the Movement possibilities of the auxiliary device can be used as a further control parameter or as a boundary condition.
  • the movement of the irradiation point and the advance of the auxiliary device in the process space are at least partially coupled, synchronized or coordinated, in particular so that the auxiliary device does not cover the irradiation point during the irradiation or does not pass through the beam path of the high-energy beam.
  • an auxiliary or support device is to be understood as meaning further devices, for example injection nozzles for shielding gases, suction devices or comparable devices which can contribute to an optimization of the production process, and coaters or application devices for building material.
  • the locally movable auxiliary device can preferably be designed so that it is essentially locally effective.
  • the effective range of the auxiliary device preferably comprises only a portion of the layer of the building material, wherein the effective range of the auxiliary device in its horizontal extension is in particular smaller than the field of construction of the device.
  • such an auxiliary device can be connected by means of a suitable suspension or a carrying mechanism to a drive unit which controls or moves the auxiliary devices according to the control data of a control device in the process space of the device.
  • a device according to the invention for additive manufacturing preferably comprises a control device which is suitable for adapting the movement of the irradiation point and the advance of at least one auxiliary direction which can be moved locally in the process space.
  • the auxiliary device is preferably moved by a horizontal movement of the auxiliary device substantially parallel to the surface of the layer, in particular such that each region of the layer or of the construction field is reached by the auxiliary device or its effective area.
  • a plurality of auxiliary devices can be arranged in a process space, which can be individually controlled and moved, wherein the feed of the individual auxiliary devices is synchronized and is also adapted to the movement of the irradiation site.
  • the method is suitable for processing heavy-weldable alloys as a building material, with a sufficient heating of the building material exerts a significant influence on the component quality.
  • the movement of the irradiation point is adapted to or follows the slower feed of a locally movable heating device. This can be achieved, for example, by the fact that the advance of the local heating device or the local heating of partial areas of the layer by the local heating device starts at a specific point in time before the beginning of the irradiation, so that a buffer is generated on already heated partial areas of the layer becomes.
  • the method also permits, in addition to a preheating, a controlled reheating of partial areas of a layer after the irradiation of these subregions has ended.
  • the feed of the auxiliary device can be adapted to or follow the movement of the irradiation site.
  • this temporally and spatially coordinated control makes it possible to increase the component quality by arranging a number of process-optimizing auxiliary devices in the process space, in particular a locally movable heating device, wherein the movement of the irradiation point and thus the Ver - Consolidation of the layer continuously or without interruption, so that the manufac turing period of a component can be reduced as possible.
  • the individual assignment of maximum widths according to the invention to the irradiation strips is also a valuable contribution.
  • At least a partial area of a cross-sectional area of the component layer is subdivided by means of a computing device into a number of virtual cross-sectional area segments, wherein a virtual cross-sectional area segment comprises a number of irradiation strips.
  • the cross-sectional area of the component layer is bounded or closed towards the outside by a contour, wherein the contour is a component of the cross-sectional area. Consequently, a virtual cross-sectional area segment is formed by at least a portion of the contour of the cross-sectional area of the component layer and at least one segment boundary to be virtually arranged.
  • the segmentation of the cross-sectional area of the component layer into individual cross-sectional area segments by the arrangement of virtual segment boundaries is effected by means of a computing device on the basis of segmentation criteria, in particular the component geometry, as will be explained in detail later.
  • the irradiation strips which are arranged to irradiate the cross-sectional area of the component layer are also segmented or subdivided into sections which are assigned to the respective cross-sectional area segments.
  • the irradiation strips, which are covered by a virtual cross-sectional area segment or are assigned to a cross-sectional area segment form an irradiation strip group.
  • the irradiation strips of a radiation strip group are solidified directly one after the other.
  • the irradiation strips are initially irradiated only in those areas which are arranged within a certain cross-sectional area segment.
  • the portions of the irradiation stripes disposed within a second cross-sectional area segment are irradiated.
  • a partial irradiation of the virtual irradiation strips takes place, wherein the irradiation is interrupted when a segment boundary and / or a contour or contour line is reached.
  • an irradiation strip is delimited by the contour not only in its length, but also with respect to the solidified width, ie. H.
  • the irradiation strip is not irradiated according to the predefined maximum width.
  • the virtual cross-sectional area segments are regarded as independent, separate, self-contained solidification units, wherein the individual irradiation strip groups are solidified successively.
  • the order of the consolidation of the cross-sectional area segments is determined by means of the computing device as part of an irradiation strategy, as will be explained in detail later.
  • the course of an "actual segment boundary" between two solidified cross-sectional area segments can deviate from the course of a corresponding virtually calculated segment boundary, the irradiation strategy being optimized.
  • the virtual segment boundary is not perpendicular to the feed direction of the solidification.
  • the segment boundary is in fact preferably solidified in such a way that it always runs along or parallel to scan lines or perpendicular to the longitudinal extent of the irradiation strips.
  • the actual segment boundary may preferentially alternate in a boundary around the virtual segment boundary.
  • each section intersects the actual Once the segment boundary is reached, the virtual segment boundary, where a section corresponds to the distance between two bends.
  • a homogeneity of the energy input into the layer can thus be increased by selecting the length and optionally the distances between the scan lines of the irradiation strips to one another as if the cross-sectional area of the component layer were solidified in continuous irradiation strips.
  • the segmentation of the cross-sectional area of the component layer in cross-sectional area segments is preferably optimized by the computing device taking into account specific or predeterminable optimization criteria.
  • the computing device is thus advantageously designed to calculate an irradiation strategy for an additive manufacturing process and to optimize it so that the component quality is increased as possible and the production time of the component is reduced.
  • the computing device may therefore preferably be designed to calculate or optimize a radiation strategy, and on the other hand to generate the control data for producing at least one component layer of a component, in particular taking into account the irradiation strategy.
  • a modification or optimization of the irradiation strategy can also take place in an already completely generated control data record, wherein a recalculation or generation of the control data is possible at any time, in particular also during the ongoing production process. It should be pointed out again at this point that both the optimization of the irradiation strategy and the generation of a control data record need not necessarily take place in a computing device of a control device or in an apparatus for additive manufacturing.
  • control data with a correspondingly optimized irradiation strategy may be generated in a control data generation device which is spatially separated from the device for additive manufacturing.
  • a preferred optimization criterion may be a reduction of a number of radiation jumps within the cross-sectional area of the device layer.
  • Another optimization criterion can be the reduction of the distance of the radiation jumps within the Cross-sectional area of the component layer relate.
  • These optimization criteria can be applied individually or in combination, eg. B. as a multi-objective optimization.
  • one of the parameters for example the number of radiation jumps or a maximum jump distance, can also be defined as a boundary condition and the optimization then takes place with respect to another parameter.
  • An irradiation jump is a change or jump of the irradiation site from an end point of the irradiation of a first cross-sectional area segment to a starting point of the irradiation of a second cross-sectional area segment.
  • the point of irradiation jumps to the starting point of the irradiation of a second cross-sectional area segment, wherein the irradiation jump preferably takes place with temporary deactivation of the irradiation.
  • the location or point at which the irradiation of the layer begins or enters the layer, be it for the first time or after a previous interruption, is also referred to as the "point of entry" of the irradiation.
  • the arrangement and / or width of the virtual irradiation strips of a cross-sectional area segment is optimized by the computing device taking into account optimization criteria.
  • a first "marginal" irradiation strip can be arranged so that its outer edge forms a tangent to an outer edge of the cross-sectional area segment.
  • the arrangement of further irradiation strips within the cross-sectional area segment can preferably take place in such a way that irradiation islands within an irradiation strip are avoided as far as possible.
  • Under irradiation islands are, as mentioned, local or separate, based on the surface of the irradiation strip areal small-scale, preferably marginal, to be solidified portions within an irradiation strip to understand.
  • the maximum width of a first irradiation strip of a cross-sectional area segment can be modified within predetermined limits so that the arrangement or virtual generation of an additional irradiation strip can be dispensed with.
  • the optimization of the virtual irradiation strips of a cross-sectional area segment with regard to their arrangement and / or width preferably takes place separately or individually for the individual cross-sectional area segments of each component layer. This means that the irradiation strips are calculated specifically for the individual cross-sectional area segments.
  • the virtual irradiation strips of two cross-sectional surface segments of a component layer can differ from one another with respect to their number, maximum width, longitudinal extent and orientation within the cross-sectional area segment.
  • the computing device is thus designed to calculate an optimized irradiation strategy for the individual cross-sectional area segments of a component cross-sectional area.
  • an optimization of the global irradiation strategy, d. H. the irradiation of the individual cross-sectional surface segments is coordinated so that the irradiation of the entire component layer cross-sectional area is also optimized.
  • a local segmentation of the cross-sectional area segment by the computing device takes place in at least two virtual partial cross-sectional area segments.
  • at least one virtual segment boundary in a region of the cross-sectional area segment can be locally canceled.
  • a local segmentation is to be understood that the arrangement of a number of local virtual segment boundaries separates at least one independent local subsegment from an original output cross-sectional area segment.
  • both of the virtual partial cross-sectional area segments formed thereby comprise at least a partial area of an irradiation strip.
  • the virtual partial cross-sectional area segments can be considered as independent cross-sectional area segments when optimizing the irradiation strategy by the computing device according to the optimization criteria described above.
  • At least one virtual segment boundary By local cancellation of at least one virtual segment boundary is achieved that at least a portion of a first virtual cross-sectional area segment detached from this cross-sectional area segment or detached therefrom and a second, preferably adjacent, cross-sectional area segment can be assigned.
  • this at least one detached portion can be considered as part of the second cross-sectional area segment.
  • the remaining segment boundaries of the cross-sectional area segmentation are retained.
  • the partial segmentation or the local cancellation of the segmentation makes it possible to optimize the irradiation strategy such that the production time of a component is reduced even further, for example by avoiding unnecessary travel paths of an auxiliary device between the cross-sectional surface segments.
  • the irradiation strategy can thereby be adapted so that the energy input into the component layer is optimized, in particular with regard to the formation of a uniform heat front during the solidification of the component layer, as will be explained in detail later.
  • the irradiation strategy according to which irradiation of at least a portion of the cross-sectional area of the component layer then takes place, is preferably performed by the calculation method.
  • the decision logic is based on a series of decision steps which are preferably, but not necessarily, processed by the computing device in the order described below:
  • the virtual segmentation of at least one subregion of the cross-sectional area of the component layer to be consolidated takes place into a number of virtual cross-sectional area segments.
  • the segmentation is preferably carried out by means of an analysis of the dimensional ratios of the cross-sectional area of the component layer, for example in terms of circumference, geometry, diameter, centroid, constrictions, bottlenecks, etc., wherein a number of virtual segment boundaries is arranged in the cross-sectional area of the component layer.
  • a threshold value can be defined by setting the area of the not to be solidified recesses within the cross-sectional area in relation to a maximum effective range of the heating.
  • Further segmentation criteria may be the definition of a maximum number of cross-sectional area segments in a layer or the determination of a minimum or maximum permissible surface area of a cross-sectional area segment.
  • the segment boundaries can be arranged essentially at right angles to the advancing direction of the solidification, which advantageously affects the homogeneity of a local energy input into the layer.
  • the segment boundaries may be arranged at a different suitable angle to the feed direction and / or to each other, insofar as a further optimization of the component quality and / or the production time can thereby be achieved.
  • a first irradiation strip is arranged in a first cross-sectional area segment starting from a reference point.
  • a reference point is to be understood as a suitable reference point within the construction field of the device.
  • a virtual reference frame is arranged in a surrounding region of the cross-sectional area of the component layer, which covers the cross-sectional area as closely as possible, wherein the virtual reference frame can be designed, for example, in the form of a rectangle, parallelogram or another suitable polygon.
  • a vertex of this virtual frame called a "bounding box" may serve as a reference point. If the cross-sectional area of the component Layer comprises a plurality of non-contiguous areas, a corresponding number of virtual bounding boxes can be arranged on the device layer.
  • a first irradiation strip is arranged so that the outer edge of the cross-sectional surface segment, for example the contour, coincides locally with the outer edge of the irradiation strip, i. H.
  • the irradiation strip forms with its outer edge a tangent to the outer edge of the cross-sectional surface segment.
  • the width of this first irradiation strip may correspond to a standard width or standard width of an irradiation strip, which lies in a predefined range between a minimum width and a maximum width.
  • the maximum width preferably corresponds at most to the width of an effective range of a heating device which ensures heating in accordance with the requirements.
  • the maximum width of an irradiation strip is 10 mm, the invention not being restricted thereto.
  • the minimum width of an irradiation strip can, in principle, assume any value greater than 0 mm, ie also be extremely narrow, with a minimum width in a range between 2 mm and 3 mm being preferred.
  • the standard width of an irradiation strip is preferably in a range between 5 mm and 8 mm.
  • the width of the first irradiation strip is optimized on the basis of defined criteria. This can preferably be realized in the following way:
  • a modification or adaptation of the previously determined virtual scan line length which here corresponds to the irradiation strip width, makes sense with regard to the virtual irradiation strips to be arranged below and / or in the sense of optimizing the irradiation strategy, ie it can an optimization of the irradiation strip maximum width.
  • the previously determined The width of the virtual irradiation strip can be increased or reduced within the predefined limits.
  • the cross-sectional area segment as a whole is taken into account, in particular with respect to the extent of the cross-sectional area segment with respect to a main extension direction of the component layer and the occurrence of geometric obstacles.
  • the test takes place on the basis of the first irradiation strip
  • the other irradiation strips to be arranged to solidify the cross-sectional area segment are also taken into account.
  • the width of the first irradiation strip is selected such that a radiation strategy that is as advantageous as possible can be calculated for the totality of the irradiation strips of a cross-sectional surface segment.
  • a test criterion may be the presence of geometric obstacles within the cross-sectional area segment.
  • this also includes constrictions or regions ("holes") that are not to be consolidated within the cross-sectional area segment.
  • holes constrictions or regions
  • the presence of holes of a specific size for example if a diameter of the hole exceeds a maximum effective range of a local heating device, should preferably be taken into account in the irradiation strategy.
  • a further test criterion is whether modifying the irradiation strip width can prevent the occurrence of irradiation islands in the first and in the subsequently to be arranged irradiation strip.
  • Irradiation islands can arise, in particular, in marginal irradiation strips by overlapping with the contour line and / or with geometric obstacles within the cross-sectional area segment.
  • the test further takes into account that the width of the irradiation strips is in a preferred range of the irradiation, whereby irradiation strip widths below the preferred minimum width should be avoided.
  • it is checked whether the number of irradiation strips required for solidifying the cross-sectional area segment can be reduced by a suitable arrangement of the irradiation strips.
  • the test may include multi-objective optimization. If several geometric obstacles occur, some of them can be weighted differently.
  • the first irradiation strip is then virtually arranged in the cross-sectional area segment based on the previously calculated data having a corresponding width.
  • at least one second irradiation strip adjoining the first irradiation strip is virtually arranged in the cross-sectional area segment by means of an iterative process.
  • a test or adaptation of the irradiation strip width according to the test logic explained above can take place.
  • the arrangement of the irradiation strips can take place in further cross-sectional area segments of the component layer, so that the entire cross-sectional area of the component layer is covered by virtual irradiation strips.
  • the above-explained steps of the check logic are preferably repeated in a higher-level iterative process or in the sense of an outer loop.
  • the virtual radiation strips are arranged with a substantially identical orientation in the individual cross-sectional surface segments, the invention not being restricted thereto.
  • the orientation of the irradiation strips can be based on the geometry of the component layer or of the cross-sectional area segment, for example, by arranging the irradiation strips substantially parallel to a main extension direction of the cross-sectional area segment or the component layer.
  • the orientation of the irradiation strategy is preferably independent of the geometry of the component layer.
  • the orientation or orientation of the irradiation strips in each successive component layer is rotated by a suitable angle (eg 67.5 °).
  • the virtual arrangement of a number of irradiation strips in the cross-sectional area segment to be consolidated can also be effected by means of a "global" decision logic.
  • a "global" irradiation strip pattern or grid starting from a reference point are virtually arranged on the construction field, that at least the entire surface of the cross-sectional surface segment is covered by virtual irradiation strips, wherein at least two irradiation strips of a layer is assigned a different maximum width.
  • the width of the virtual irradiation strips can preferably correspond to the standard width.
  • the width of one or more irradiation strips i. H. the length of the virtual scan lines arranged within the irradiation strips can be modified. At least a modification of the irradiation strip width can take place to the extent that particularly narrow irradiation strips with a less preferred width, for example in a range between 0 mm and 3 mm, are avoided as far as possible.
  • the homogeneity of the energy input into the layer can thereby be optimized.
  • the computing device calculates an irradiation strategy for irradiating the cross-sectional area of the component layer on the basis of the previously determined data or decisions.
  • the irradiation strategy takes into account all process processes that may be involved in the solidification of a component layer, for example the irradiation and heating of the building material, the method of auxiliary devices in the process space, etc. Therefore, the irradiation strategy can also be synonymously referred to as a hardening strategy.
  • the irradiation strategy is preferably calculated or optimized in such a way that attention is paid to certain process criteria which have a particular influence on the quality of a component or additive manufacturing product. These include in particular the following criteria:
  • a heat front means the propagation of heat in the layer, for example caused by the irradiation and / or the heating, along a certain direction, ie it becomes describes a "global" entry or “global” propagation of heat, e.g. B. related to the entire layer or component layer.
  • the irradiation strategy is calculated or optimized by the computing device on the basis of further optimization criteria
  • Cross-sectional area of the component layer so that the cross-sectional surface segments have a particularly favorable arrangement or position to each other, in particular the distance and the number of radiation jumps for irradiation of the entire cross-sectional area are reduced as possible.
  • the two latter criteria are considered together or weighed against each other, so that a check is made as to whether the criterion of a uniform heat front in the component layer or the shortest possible distance of the radiation jumps priority is given.
  • the irradiation strategy can thus be optimized with regard to the parameters "production time” or "quality" of the component. Such a decision can also be made by presetting on the instructions of a user.
  • a meandering or rectified irradiation of the irradiation strips is advantageous.
  • a change between meandering and rectified irradiation can also take place within a segment.
  • consideration is given to whether a local Segment segmentation or local partial segmentation can be carried out to optimize the irradiation strategy.
  • a plurality of solidification layer regions can also be arranged in one layer, wherein the solidification layer regions can belong to a single component or a plurality of separate components. Therefore, the decision logic can preferably also take into account an advantageous sequence of solidification of the individual solidification layer areas. Preferably, those solidification layer regions in a layer which belong to one and the same component can be combined to form an irradiation or solidification group.
  • the individual solidification layer areas of a component which correspond to a solidification group can each be solidified directly one after the other or successively.
  • the order of solidification can be determined individually on different observation levels. This means that both an order of execution of the solidification groups in a layer and an order of solidification of the solidification layer regions of an arbitrary component or a solidification group can be defined as a function of defined criteria.
  • a preceding solidification layer region is to be understood as meaning a solidification layer region in a layer which has been irradiated immediately before, which directly adjoins a solidification layer region currently to be solidified of an overlying layer.
  • the preceding and the current solidification layer region preferably belong to one and the same component, but in each case lie in different layers.
  • a further criterion could be the inherent stresses occurring in one or more components as a function of the sequence of solidification of the solidification layer regions.
  • such residual stresses can be simulated by means of suitable software or software program parts before the start of solidification.
  • one Simulation of expected overheating or detection of actual temperature conditions or overheating in a layer currently to be consolidated due to a high energy input into one or more previously solidified, underlying layers by means of a process monitoring device can serve as an optimization criterion.
  • a cross-sectional area segment having, for example, a plurality of different irradiation strip widths may be assigned to the individual irradiation strips, depending on their respective width, specific energy input parameter sets.
  • At least one energy input parameter for example a power or speed with which a solidifying high-energy beam is driven, can be optimized to a certain width of the irradiation strip so that, for example, the most homogeneous possible energy input is achieved within the individual irradiation strips and / or local temperature peaks are avoided.
  • the irradiation strategy calculated and optimized on the basis of these criteria is taken into account or flows into the generation of the control data.
  • the control data generated by the computing device can then be transmitted to the control unit of the device for additive manufacturing, wherein by means of the control unit, a corresponding irradiation control protocol is calculated so that the manufacture of the component can then take place according to the irradiation strategy or the control data.
  • the calculation and optimization of the irradiation strategy, as well as the generation of the control data can take place before or during the production process, for example by calculating or optimizing the irradiation strategy of a further subsequent component layer during solidification of a first component layer.
  • the calculation and optimization of the irradiation strategy can, as described above for the generation of the control data, also be effected by means of an external computing unit, which is not part of the apparatus for additive manufacturing or is not connected directly to it.
  • the build-up material of a layer in each case at least in one region of the moving irradiation point, at least before the irradiation, can preferably be heated by means of a locally movable heating device.
  • the locally displaceable heating device can preferably also be embodied substantially locally effectively, in particular in such a way that only one certain, defined portion of the layer is selectively heated.
  • the heating or heating of the build-up material to a predetermined target temperature immediately before the irradiation by the irradiation unit in particular so that the building material in the heated area at the beginning of the irradiation already has a predetermined target temperature.
  • the heating or the predetermined setpoint temperature in the building material can also be maintained during and / or after the irradiation.
  • the local heating of the building material is carried out by means of induction.
  • An induction coil arrangement which comprises at least two separate induction coils, ie. H. the heating device can be realized in the form of an induction coil arrangement.
  • the induction coils are characterized by a different inner diameter, so that the effective range of the heating in the building material is also different.
  • the effective range of the heating of this induction coil arrangement is limited insofar as only a portion of the layer is always heated at a time. Initially, only one area of a building substrate and / or an already solidified, d. H. heated below the layer currently to be consolidated layer. Subsequently, due to conduction and thermal radiation, the uppermost, d. H.
  • the induction coils In order to heat the entire layer, the induction coils must therefore be movable in the process space, in particular so that each area of the layer can be reached or heated by both induction coils. Therefore, the two induction coils are preferably mounted to be adjustable relative to one another at a suitable distance above the layer, in particular in such a way that the individual heating areas of both induction coils can be superimposed in a common area of the building material or not.
  • temperatures of, for example, between 800 ° C. and more than 1200 ° C. in the building material can be achieved.
  • other heating devices which are suitable for heating the build-up material to a predetermined desired temperature can also be used, for example a defocused laser or electron beam.
  • the heating that the temperature in the build-up material increases less sharply or abruptly at the beginning of the irradiation and decreases less sharply or suddenly after termination of the irradiation.
  • the temperature difference in the building material between a time before and after and during irradiation significantly lower than without such a heater. This has a positive effect on the component quality by z. B. cracking in the component during the additive manufacturing can be reduced.
  • the heating of the building material takes place at least in one area of the irradiation site.
  • the effective range of the heating can be made substantially larger.
  • the width of an irradiation strip preferably corresponds at most to the width of an effective region of a heating device, which ensures the achievement of a desired temperature of the heating in the building material. This ensures that the irradiation strip can be heated in accordance with its entire width.
  • the target temperature to be achieved can be predetermined, for example, depending on the build-up material, and is present in the build-up material at least at the beginning of the irradiation in the effective range of the heating device.
  • the width of the effective range of the heating refers to the same spatial direction as the width of the irradiation strip, d. H. both are measured in the same spatial direction.
  • a maximum value of the maximum width of an irradiation strip is defined, wherein the irradiation strip can not be enlarged or broadened beyond this maximum value.
  • this maximum value preferably corresponds to the maximum width of the effective range of the heating device, whereby in principle also other hardware conditions of the device come into consideration as control parameters. Under certain circumstances, however, it may also be advantageous that the effective range of the heating device is significantly greater than the maximum width of an irradiation strip, in particular if the heating device is realized in the form of an induction coil arrangement.
  • the maximum value of the maximum width of a radiation stripe can also be defined on the basis of further criteria, for example a radiation intensity, a speed with which the irradiation point is moved over the surface of the layer, an irradiation power, an energy input quantity the layer, etc., to z. B. prevent local overheating in the layer.
  • the maximum value of the maximum width of the irradiation strips is redetermined for each layer.
  • the definition of a maximum value of the maximum width of an irradiation strip achieves that the entire surface of each irradiation strip to be irradiated has a suitable predetermined setpoint temperature before the start of the irradiation, which, as explained above, has a positive effect on the component quality.
  • the setpoint temperature of the heating in the building material is preferably at least 50%, particularly preferably at least 70%, very particularly at least 80%, in particular preferably at least 90% of a solidification temperature of the building material.
  • the solidification temperature or solidus temperature is to be understood as the temperature at which the construction material undergoes a phase transformation between the states of matter "liquid” and "solid". The solidification temperature thus corresponds essentially to the melting temperature.
  • the heating temperature is preferably selected such that cracking or hot cracking in the component during additive production is avoided.
  • the setpoint temperature may be present at least at a starting time of the irradiation in the build-up material, wherein the provision of the setpoint temperature at a point in time during and / or after the irradiation is likewise preferred.
  • the target temperature may be maintained for a period of 1 to 5 seconds after the irradiation site has passed a position, with a desired cooling rate of the component or a holding period of the setpoint temperature in advance in tests, among other things Building material, can be determined.
  • the setpoint temperature of the heating is largely determined by the nature of the building material to be consolidated.
  • the method is particularly preferably suitable for the additive production of components based on "hard-to-weld” alloys, which are also referred to as “high-performance alloys” or “high-temperature materials”. These are understood to mean those building materials which are distinguished in the finished component by high mechanical strength and corrosion resistance at high temperatures. At the same time, these building materials tend to crack in the component during processing in additive manufacturing processes, for example in DMLS or SLM processes.
  • hard-to-weld alloys are characterized by high melting points, which can be in the range of over 1340 ° C.
  • the process is particularly suitable for processing alloys on nickel or cobalt-based, but the invention should not be limited thereto.
  • the method is equally suitable for processing further, preferably pulverulent, building materials, such.
  • building materials based on ceramics, metallic glasses or alternative metals, wherein the metal content in the building material is at least 50%, and other conventional building materials used in additive manufacturing processes.
  • the construction materials can also be fiber-reinforced.
  • FIG. 1 shows a schematic view, partly in section, of an exemplary embodiment of a device according to the invention for the additive production of manufactured products
  • FIGS. 2 and 3 show a schematic representation of the solidification of a component layer in an additive manufacturing process according to a method of the prior art
  • FIG. 4 shows a schematic representation of the solidification of a region of the component layer within a virtual irradiation strip according to an embodiment of the production method according to the invention
  • FIG. 5 a schematic representation of the solidification of a component layer according to an embodiment of the production method according to the invention
  • FIG. 6 a schematic representation of the segmentation of the cross-sectional area of a component layer in cross-sectional area segments according to an embodiment of the production method according to the invention
  • FIG. 7 a schematic representation of the segmentation of the cross-sectional area of a component layer in cross-sectional area segments according to a further embodiment of the production method according to the invention
  • FIG. 8 shows a schematic representation of the segmentation of the cross-sectional area of a component layer in cross-sectional surface segments according to a third embodiment of the manufacturing method according to the invention
  • FIG. 9 shows a schematic representation of the arrangement of virtual irradiation strips on a component cross-sectional area according to an embodiment of the inventive production method
  • FIG. 10 shows a schematic representation of the solidification of a region of the component layer within a virtual irradiation strip in the region of a segment boundary according to an embodiment of the production method according to the invention
  • FIG. 11 shows a flowchart of an exemplary embodiment of a method according to the invention for calculating or optimizing an irradiation strategy for the additive production of production products.
  • the device will be briefly referred to as a "laser sintering device” 30 without any restriction of generality.
  • Such a laser sintering device 30 is shown schematically in FIG.
  • the device has a process chamber 32 or a process chamber 32 with a chamber wall 33 in which substantially the manufacturing process takes place.
  • a process chamber 32 In the process chamber 32 there is an upwardly open container 34 with a container wall 35.
  • the upper opening of the container 34 forms the respective current working plane 36.
  • the lying within the opening of the container 34 area of this working plane 36 is referred to as building field 37 and can be used to construct the object 31.
  • the container 34 has a movable in a vertical direction V base plate 39 which is arranged on a carrier 38.
  • the base plate 39 closes the container 34 down and thus forms its bottom.
  • the base plate 39 may be integral with the carrier, but it may also be a plate formed separately from the carrier 38 and secured to or simply supported by the carrier 38.
  • a construction platform 40 may be attached as a construction document on which the object 31 is constructed. In principle, however, the object 31 can also be constructed on the baseplate 39 itself, which then forms the construction substrate.
  • the basic structure of the object 31 is such that a layer of building material is first applied to the building platform 40, then - as explained later - with a laser at the locations which are to form parts of the object to be manufactured, the building material is selectively solidified , then with the aid of the carrier 38, the base plate 39, thus the building platform is lowered and a new layer of the building material applied and then selectively solidified, etc.
  • the object 31 built on the platform 40 in Figure 1 is below the working level 36th in an intermediate state. It already has several solidified layers and is surrounded by an unconsolidated building material 41.
  • Various materials can be used as build-up material 41, preferably powders, in particular hard-to-weld alloys based on metal powder, ceramic powders and metallic glasses and comparable materials.
  • Fresh build-up material 43 is located in a storage container 42 of the laser sintering device 30. With the aid of a coater 44 movable in a horizontal direction H, the build material 43 can be applied in the work plane 36 or within the build field 37 in the form of a thin layer. Reservoir 42 and coater 44 may be considered as components of a feeder for applying a build material layer.
  • a global heating device 45 is located in the process chamber 32. This can serve for heating the applied build-up material 43, wherein essentially the building material 43 is heated in the entire construction field 37. The amount of basic energy introduced into the building material by the global heater 45 is below the necessary energy at which the building material sinters or even melts.
  • the local heating device 46 is arranged at a defined distance above the building field 37.
  • the local heating device 46 can be realized, for example, in the form of one or more induction coils and can be moved substantially horizontally, ie parallel to the working plane 36, in the process chamber 32 or the process space.
  • the local heating device 46 is configured to extend the building material 43 partially, ie in a defined subarea of the field 37, for example in a subregion of a component layer or component cross-sectional area, preferably to a temperature in the region of the solidification temperature of the building material heat.
  • the laser sintering device 30 has an irradiation unit 50 with a laser 51.
  • the laser 51 generates a laser beam 52, which is deflected by a deflecting device 53 in order to selectively introduce energy into the respectively selectively to be solidified areas of the layer according to the irradiation strategy. Further, this laser beam 52 is focused by a focusing device 54 on the working plane 36 in a suitable manner.
  • the irradiation unit 50 is preferably located outside of the process chamber 32, and the laser beam 52 is guided into the process chamber 32 via a coupling window 55 attached to the upper side of the process chamber 32 in the chamber wall 33 and impinges on the working chamber at an irradiation point BL. level 36, d. H.
  • the irradiation unit 50 may comprise not just one but a plurality of lasers. Preferably, this may be gas or solid state lasers or any other type of laser such. As laser diodes act, in particular VCSEL (Vertical Cavity Surface Emitting Laser) or VECSEL (Vertical External Cavity Surface Emitting Laser) or a line of these lasers.
  • VCSEL Vertical Cavity Surface Emitting Laser
  • VECSEL Vertical External Cavity Surface Emitting Laser
  • the laser sintering device 30 here furthermore contains a sensor arrangement 64 which is suitable for detecting a process radiation emitted during the impingement of the laser beam 52 onto the build-up material 43 in the working plane 36.
  • This sensor arrangement 64 operates spatially resolved, ie it is capable of detecting a type of emission image of the respective layer.
  • an image sensor or a camera is used as the sensor arrangement 64, which in the region of the emitted radiation is sufficiently sensitive.
  • one or more sensors for detecting an optical and / or thermal process radiation could also be used, eg. B. photodiodes, which detect the emitted from a molten pool under incident laser beam 52 electromagnetic radiation, or temperature sensor for detecting an emitted thermal radiation.
  • the signals detected by the sensor arrangement 64 are transferred here as a process space sensor data record SDS to a control device 60 of the laser sintering apparatus 30, which also serves to control the various components of the laser sintering apparatus 30 for the entire control of the additive manufacturing process.
  • the control device 60 comprises a computing device 62 for the layered calculation or optimization of an irradiation strategy for the selective solidification of a component layer.
  • the computing device 62 may include a control data generation device 65 for generating process control data PS.
  • control data PS could also be externally, i. H. be generated outside the computing device 62 or the laser sintering device 30.
  • the control data generating device 65 in an external data processor, e.g. B. be implemented in a terminal 70, wherein the control data PS of the control device 60 are supplied from the outside, for example via a bus 71.
  • the computing device 62 a change or optimization of the control data PS, in particular with respect Irradiation strategy, done.
  • the control data PS could also be used directly, i. H. without a change by the computing device 62, are passed to the control unit 63.
  • the control device 60 is preferably constructed in such a way that the irradiation strategy or the control data PS is determined directly in the computing device 62, specifically in the manner described below, and used to solidify the component layer.
  • the control unit 63 controls the components of the irradiation unit 50 in the usual way, namely here the laser 51, the deflection device 53 and the focusing device 54 and, for this purpose, transfers to them correspondingly irradiation control data BS.
  • the control unit 63 also controls the global radiation heater 45 by means of suitable global heating control data HSG, the carrier 44 by means of coating control data ST, the carrier 38 by means of carrier control data TS, and the local heating device 46 by means of local heating control data HSL.
  • the control device 60 may comprise a further control device 61, which determines the quality data QD using (externally generated) process control data PS and the process space sensor data set SDS or other suitable process data, for example, in a variant also to the computing device 62 can be transferred in order to be taken into account in the irradiation strategy and thus to be able to intervene in the additive manufacturing process.
  • the controller 60 is here z. B. via a bus 71 or other verbin- Phyg coupled to a terminal 70 with a display or the like.
  • a terminal 70 with a display or the like.
  • An operator can use this terminal to control the control device 60 and thus the entire laser sintering device 30.
  • the display of the terminal 70 can also be used during the ongoing production process for visualizing the irradiation strategy of the computing device 62 and / or the process space sensor data set SDS and / or the quality data QD and for supplying control data PS to the laser sintering device 30.
  • the present invention is not limited to such a laser sintering device 30. It can be applied to any other methods for generatively or additively producing a three-dimensional object by, in particular layer-by-layer, applying and selectively solidifying a build-up material, wherein a high-energy beam is emitted for solidification onto the build-up material to be solidified.
  • the irradiation unit may not only be a laser as described herein, but any means may be used to selectively apply energy as wave or particle radiation to the building material. For example, instead of a laser, another light source, an electron beam, etc. could be used. FIG.
  • FIG. 2 shows schematically the solidification of a component cross-sectional area 3 of an additive component according to a manufacturing method according to the prior art.
  • a layer of a build-up material (not shown) is applied.
  • On the surface of the layer a number of irradiation strip 1 is arranged virtually *, wherein the irradiation strips 1 are here arranged in parallel *, and the width a of the irradiation strips 1 * is substantially equal.
  • the irradiation strips 1 * are outwardly, ie in their width, by each bounded two outer edges 2.
  • the cross-sectional area of the component layer 3 to be consolidated is limited to the outside, ie to the part of the layer which is not to be consolidated, by a contour 4 or contour line.
  • the solidification of the component layer takes place along the irradiation strips 1 * , wherein the irradiation strips 1 * here are irradiated or solidified in a meandering manner in accordance with a feed direction VV of a solidification region. In this case, irradiation of the layer takes place by moving the irradiation point BL along scan lines 5.
  • the irradiation strips 1 * are irradiated only in a region within the cross-sectional area 3 of the component layer.
  • FIG. 3 schematically shows a production method for solidifying a component cross-sectional area 3 according to the method according to FIG. 2 (ie according to the prior art), in which case the component layer is characterized by a more complex cross-sectional area 3.
  • the irradiation of a first virtual irradiation strip 1 * takes place by advancing the solidification area corresponding to the feed direction VV. In some subregions of the irradiation strip 1 *, there is no or only a slight overlap of the cross-sectional area 3 with the surface of the irradiation strip 1 * .
  • sections are formed along the first irradiation strip 1 * in which no irradiation of the virtual irradiation strip 1 * takes place .
  • These sections can be interrupted by isolated areas to be irradiated or irradiation islands 9, 9 '.
  • an irradiation jump therefore takes place over a first distance b, ie the irradiation point BL is moved over the distance b with temporary deactivation of the irradiation, wherein the irradiation in the area of the irradiation island 9 resumes or in the component layer is inserted.
  • a second irradiation jump takes place over a distance b 'corresponding to the direction RB for irradiation of the layer in the region of a second irradiation island 9'.
  • the irradiation jump is to be understood as a "global" jump, ie the irradiation point BL jumps from a first subarea of an irradiation strip 1 * to a remote second subarea, whereby an intermediate subarea of the irradiation strip 1 * is not irradiated.
  • the irradiation strip 1 * is here in three separate sections discontinuous, ie solidified with temporary interruption of the irradiation.
  • FIG. 4 shows, in sections, the solidification of a region of the component layer within virtual irradiation strips 1, 1 'according to an embodiment of the production method according to the invention.
  • a number of scanning lines 5 running essentially parallel to one another are arranged.
  • the scan lines 5 can be arranged in a first irradiation strip 1 (shown here on the left) substantially perpendicular to the feed direction VV of the solidification region or in a further irradiation strip T (shown here on the right) at another suitable angle.
  • an irradiation point BL is moved along scan lines 5 within the irradiation strips 1, 1'.
  • the irradiation point BL is moved through the component cross-sectional area 3 in accordance with the direction VS of the scan lines 5, the course directions VS of the scan lines 5 being rectilinear in a first irradiation strip 1 or rectified in a second irradiation strip T, ie in the same Orientation, are arranged.
  • the advancement of the solidification region takes place along the irradiation strips 1, 1 'corresponding to the feed direction VV.
  • the different type of hatching with the scan lines 5 in the two irradiation strips 1, 1 ' has been selected for FIG. 5 in order to illustrate different methods. In principle, however, all irradiation strips, even if they have different widths, can be traversed with similar or the same "hatching types".
  • FIG. 5 shows the solidification of a cross-sectional area 3 of the component layer according to a preferred embodiment of the production method according to the invention.
  • a locally movable and in particular also locally effective heating device 46 represented schematically as an induction coil, participates in the solidification of the component layer.
  • the local heating device 46 comprises at least one heating element 47 and a heating element carrier 48.
  • the heating element carrier 48 of the local heating device 46 is connected to a drive unit of the laser sintering device 30, preferably within the process chamber 32, such that the local heating device 46 according to heating control data HSL in the process space 32 is movable locally (see Figure 1).
  • the maximum width a of the irradiation strip 1 is determined by the width 8 of the maximum effective area 7 of the heating in the building material by the heating device 46 , Which effective range 7 in turn of the dimensions of the heating element 47 of the local heater 46, here z. B. the induction coil can depend. It should again be noted at this point that the effective range 7 of the heating device 46, unlike shown here, also significantly greater than the maximum width a of the irradiation strip 1 may be.
  • the heating device 46 is moved along an irradiation strip 1 in accordance with the feed direction VH of the heating device 46 over the cross-sectional area 3 of the component layer.
  • the irradiation of the scan lines 5 along the course direction VS takes place in this embodiment perpendicular to the feed direction VH of the heating device.
  • This means that the irradiation or the movement of the irradiation point BL is adapted to the advance or the travel distance of an auxiliary device which can be moved locally in the process space, here in particular the local heating device 46.
  • the feed rate VH of the heating device 46 it is possible for the feed rate VH of the heating device 46 to follow the advance VV of the fixing, i. H. the heating device 46 is moved or advanced in an area behind the irradiation point BL.
  • the feed VV of the solidification takes place below a viewing window of the heating device 46 which is transparent and / or transparent to the laser beam.
  • the heating device 46 may be annular, for example. Accordingly, in a plan view of the construction field, the irradiation point BL can always be located within an annular opening or recess of the heating device 46, which, for example, can be formed by the heating element 47 as shown here.
  • FIG. 6 schematically shows the segmentation of a component cross-sectional area 3 into virtual cross-sectional surface segments 10, 10 ', 10 "according to an embodiment of the production method according to the invention.
  • the same cross-sectional area was chosen for this purpose as in the example in FIG. 3, by means of which a method according to the prior art was explained, wherein in FIG.
  • the cross-sectional area 3 of the component layer is subdivided into a number of cross-sectional area segments 10, 10 ', 10 "by means of a computing device 62 (see FIG. 1) in such a way that the irradiation strategy for the component layer can be optimized.
  • a division into three cross-sectional area segments 10, 10 ', 10 ", a left segment 10, a middle segment 10' and a right-arranged segment 10" takes place in FIG. 6 as an example.
  • cross-sectional surface segments 10, 10 ', 10 " are delimited by virtual segment boundaries 11 or by the contour 4 of the component cross-sectional area 3 in their areal extent.
  • the segment boundaries 11 run essentially perpendicular to the feed direction VV of the solidification, and a different orientation can also be selected to optimize the irradiation strategy.
  • the orientation of the irradiation strips 1 here is substantially parallel to a previously freely defined main extension direction E of the component layer or component cross-sectional area 3, wherein the method according to the invention is not limited thereto.
  • the main extension direction E essentially corresponds to a direction of the greatest horizontal extent of the component layer or component cross-sectional area 3 and defines the length of the component layer or component cross-sectional area 3, at right angles to the width of the component layer or construction - Partial cross-sectional area 3 is defined.
  • the radiation strips 1 could also be arranged with a different orientation in the segments 10, 10 ', 10 ". It should be noted at this point that, for reasons of clarity, the scan lines that are irradiated to solidify the component layer are not shown here and in FIGS. 7 to 9 described below. In order to optimize the irradiation strategy, by means of the computing device 62 (see FIG.
  • a *** of the irradiation strips 1 is within a preferred range of irradiation (e.g. 5-8 mm).
  • a preferred maximum width a for example 8 mm
  • some of the virtual irradiation strips 1 with a different, ie a smaller width a ', a ", a *** (eg 6 mm, 5 mm, 3 mm) become in the segment 10, 10 ', 10 "virtually arranged.
  • this can be achieved by avoiding the occurrence of irradiation islands 9 (see FIG. 3) in the irradiation strip 1 of the segment 10, 10 ', 10 ", wherein the number of irradiation strips 1 used to solidify the segment 10, 10', 10 "is needed, is reduced.
  • an advantageous sequence of irradiation of the segments 10, 10 ', 10 "as well as a starting point 12 and an end point 14 of the solidification of the component layer can be determined by the computing device 62 (see FIG. 1).
  • the solidification of the segment 10 by meandering advancement of the current solidification region along the feed direction W takes place, wherein the advancement of the solidification region along the irradiation strip 1 when reaching the contour 4 of the construction Partial cross-sectional area 3 or the segment boundary 11 ends or a change to the next irradiation strip 1 of the segment 10 takes place.
  • the irradiation strips 1 of the segment 10 are successively solidified as a unit or irradiation strip group 16 (see FIG. 7).
  • the irradiation strategy can also be used to determine how or where an irradiation jump takes place at a change point 13. As shown in FIG. 6, the irradiation jump starting from the change point 13 can take place into different regions of the segment 10 'to be subsequently irradiated, ie the irradiation can jump into the segment 10' at an entry point 19 or 19 '. Accordingly becomes also the solidification region according to a direction RB or RB 'advanced. At a change point 13, therefore, the change of the irradiation or the solidification of a first cross-sectional area segment 10 to a second cross-sectional area segment 10 'takes place.
  • the change of irradiation from the first segment 10 to the middle segment 10 'to the point of entry 19' takes place.
  • the virtual irradiation strips 1 with different maximum widths a, a ', a ", a"', a * , a ** , a *** are arranged in the middle segment 10 ', wherein here also an enlargement of the maximum irradiation strip pear - te a "', a ** (eg 10 mm, 9 mm) takes place.
  • the irradiation strips of the segment 10 ' are all arranged in a range between a predefined minimum or maximum value of the irradiation strip width (for example 3 mm to 10 mm), with the previously explained criteria for optimizing the irradiation strategy being used.
  • a virtual local partial segmentation also takes place in the middle segment 10 '.
  • the virtual segment 10 ' is again sub-segmented, i. H.
  • two additional local segment boundaries 1 1 are virtually arranged (illustrated here as an example perpendicular to one another and upper right in the middle segment 10 '), so that two, in the sense of the irradiation strategy independent or independent, sub-segments of the middle segment 10 'arise.
  • one of the sub-segments essentially corresponds to the original segment 10 ', the segment 10' being reduced by the area or the area of the second local sub-segment LT.
  • at least one virtual irradiation strip 1 is arranged.
  • the maximum width a "'of an irradiation strip 1 can be increased such that instead of two irradiation strips 1 only one irradiation strip 1 is solidified, so that at least in the region of local sub-segment LT the number of virtual irradiation strips is reduced.
  • the irradiation jump or the change of the consolidation between the two sub-segments, starting from a change point, is not shown explicitly in this case, but takes place by continuous advancement of the solidification area along the feed direction VV of the irradiation strip 1 over the virtual local segment boundary 11 ".
  • a local cancellation of the segment boundary 11 takes place here as an example to optimize the irradiation strategy the middle segment 10 'is extended by the area LA of the local extension segment by the arrangement of two local, in the example mutually perpendicular, segment boundaries 11 ".
  • the area LA is actually part of the right segment 10 ".
  • the region LA is virtually attributed to the middle segment 10 'and is also solidified together with this segment 10'.
  • an irradiation jump according to one of the jump directions RB or RB' can then take place by means of a decision logic to solidify the adjacent remaining right segment 10 ".
  • the change of irradiation according to the jump direction RB takes place to the entry point 19 of the right segment 10 ".
  • the irradiation of the irradiation strips 1 of the right segment then ends at an end point 14.
  • the solidification of the three cross-sectional area segments 10, 10 ', 10 "or the component cross-sectional area 3 is thus completed.
  • the feed direction VV of the solidification region within a segment 10, 10 ', 10 " can be changed, for example as a function of geometrical obstacles in the segment.
  • FIG. 7 shows a component layer with the same cross-sectional area 3 as in FIG. 6, but within a cross-sectional area segment 10, 10 ', 10 "of the cross-sectional area 3 additionally two areas or recesses not to be consolidated or holes 15, 15 'of different sizes are arranged.
  • a first hole 15 lies completely within an irradiation strip 1, ie its diameter in a direction of the course of scan lines (not shown) or in a direction perpendicular to the longitudinal extent of the irradiation strips 1 is less than the width 8 of a maximum effective area 7 of the locally acting heater 46 (see FIG. 5).
  • the irradiation strip 1 is solidified in accordance with the feed direction VV of the solidification region, the hole 15 remaining unconsolidated. It may be "overrun" by an auxiliary device, such as a local heater 46 (see FIG. 5), without a need for directional change, while the scan line segments (not shown) located on both sides of the hole 15 in the example may be provided with a corresponding one Interrupt irradiated or solidified.
  • a second hole 15 'in a direction perpendicular to the longitudinal extent of the irradiation strips 1 is greater than the maximum effective range of a heating device 46 (see FIG. 5), so that the hole 15' is not easily detached from the auxiliary device.
  • a local heating device 46 see FIG. 5 can be "overrun".
  • the irradiation strategy is therefore adapted or optimized accordingly here:
  • the meandering hardening of the irradiation strips 1 is interrupted, wherein a change of solidification according to the jump direction RB to an irradiation strip T arranged underneath takes place initially only partially, ie in a right of the hole 15 'located portion is solidified.
  • FIG. 8 shows an alternative possibility of segmenting a component cross-sectional area 3 with the same contour as in FIGS. 6 and 7 in three cross-sectional area segments 10, 10 ', 10 ".
  • the virtual segment boundaries 1 1 are oblique, that is, H. not at right angles, arranged opposite to the virtual irradiation strip 1.
  • a local cancellation of segment boundaries or a local partial segmentation within the cross-sectional surface segments 10, 10 ', 10 ", as shown for example in FIG. 6, can be dispensed with, whereby nevertheless an advantageous one or optimized irradiation of the component cross-sectional area 3 is made possible.
  • a reference frame or a "bounding box” 17 is arranged in a surrounding area of the cross-sectional area 3 of the component layer (FIG. 9).
  • the bounding box 17 is preferably formed at right angles and surrounds the contour 4 as closely as possible so that it can not be distorted. fixing area between the bounding box 17 and the contour 4 is as low as possible.
  • a corner point 18 of the bounding box 17 can serve as the reference point 18, from which an outer edge 2 of a marginal irradiation strip 1 is virtually displaced in the direction of the cross-sectional area 3 of the component layer until the outer boundary 2 forms a tangent to the contour 4.
  • the further irradiation strips 1 are arranged in accordance with the optimization criteria explained above.
  • FIG. 10 shows a preferred procedure for solidifying irradiation strips 1, T in the region of a segment boundary 11, 1 for a subregion of the component cross-sectional area 3.
  • the computing device 62 can also be used to virtually arrange a virtual segment boundary 11 with a curved course on the component cross-sectional area 3.
  • the virtual segment boundary 11 does not extend at least in sections perpendicular to the feed direction VV of the solidification region.
  • the scan lines 5, 5 ', 5 can therefore be of different lengths in the area of the virtual segment boundary 11.
  • the irradiation strip 1 at least in a region of the virtual segment boundary, is only partially, i. H. not according to its maximum width, is irradiated. As a result, an energy input into the layer in this region of the irradiation strip 1 would be less homogeneous.
  • the course of a virtual segment boundary 11 can therefore be further optimized, preferably locally, by the computing device 62 (see FIG. 1) in addition to the previously explained optimization criteria.
  • the computing device 62 converts a locally curved course of a virtual segment boundary 11 into a stepped course of an actual segment boundary 1, as will be explained below.
  • the actual segment boundary 1 is preferably arranged along or parallel to scan lines 5, 5 ', 5 "or essentially perpendicular to the longitudinal extent of the irradiation strip 1.
  • each section of the actual segment boundary 11 intersects once the virtual segment boundary 11, where a section is understood to be the area of the actual segment boundary 11' in the region or on the outer edge 2 of the irradiation strip 1.
  • FIG. 1 1 shows a greatly simplified flow diagram of the checking or decision logic of the computing device 62 (see FIG. 1) for the calculation of an optimized irradiation strategy of a component layer of a component according to an embodiment of the method according to the invention.
  • the decision logic explained below is run through in layers, ie separately for each layer of a component to be consolidated, whereby the calculation of the irradiation strategy can take place before the beginning or even during the additive manufacturing process.
  • Process control data PS of a component layer can be supplied to the computing device as input parameter of the check logic.
  • the computing device 62 can already be supplied with predominantly ready-generated control data PS which, for B.
  • a virtual segmentation of at least one subarea of the component cross-sectional area into a number of virtual cross-sectional area segments can be carried out.
  • a first marginal radiation strip having a standard width can then be virtually arranged in a first cross-sectional area segment.
  • the irradiation strip width is then optimized according to one of the optimization criteria explained above.
  • this first edge-exposed irradiation strip can then be arranged virtually with an optimized width in the cross-sectional area segment.
  • a further irradiation strip with a standard width adjoining the first irradiation strip can be arranged virtually in the cross-sectional area segment.
  • an optimization of the irradiation strip width in a process step BTO is preferably also carried out for this further irradiation strip so that the irradiation strip can be arranged corresponding to an optimized width in the cross-sectional area segment.
  • the computing device checks whether the surface of the cross-sectional area segment is already completely covered by virtual irradiation strips.
  • the above-described iterative process SF1 is run through until it is determined in test step PF1 that a sufficient number of virtual irradiation strips are arranged in the cross-sectional area segment arranged irradiation strips then each adjacent to the immediately preceding arranged virtual irradiation strip.
  • the decision logic concludes with a step STB in which the computation device 62 (see FIG. 1) calculates and optimizes a radiation strategy for irradiating the cross-sectional area of the device layer on the basis of the previously determined data, the irradiation strategy then being implemented in the control data set PS can be.
  • the figures described in detail above are merely exemplary embodiments which can be modified by the skilled person in a variety of ways without departing from the scope of the invention.
  • the use of the indefinite article "on” or “one” does not exclude that the characteristics in question may also be present multiple times.
  • the term “unit” does not exclude that it consists of several interacting sub-components, which may possibly also be spatially distributed.

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Abstract

L'invention concerne un procédé et un dispositif pour générer des données de commande (PS) pour un dispositif (30) pour la fabrication additive d'au moins une couche d'au moins une pièce (31) dans un procédé de fabrication, dans lequel au moins une couche d'un matériau de construction est introduite dans une chambre de traitement (32) et le matériau de construction de la couche est solidifié sélectivement par irradiation d'au moins une zone partielle de la couche au moyen d'une unité d'irradiation (50). Les données de commande (PS) sont établies de manière telle que le dispositif (30) pour la fabrication additive est commandé de sorte que, pour la solidification, un site d'irradiation (BL) est déplacé par l'unité d'irradiation (50) le long d'un certain nombre de lignes de balayage (5, 5', 5'') d'une ou de plusieurs bandes d'irradiation (1, 1', 1''). Chacune de ces bandes d'irradiation (1, 1', 1'') présente une largeur maximale prédéfinie (a, a', a'', a''', a*, a**, a***), les lignes de balayage (5, 5', 5'') s'étendant dans la largeur maximale (a, a', a'', a''', a*, a**, a***) de la bande d'irradiation (1, 1', 1'') et sensiblement transversalement par rapport à une direction d'avancement (VV) d'une zone de solidification de la bande d'irradiation (1, 1', 1''). Une largeur maximale différente (a, a', a'', a''', a*, a**, a***) est attribuée à au moins deux bandes d'irradiation (1, 1', 1'') d'une couche, en fonction d'un paramètre de régulation, en particulier d'une géométrie de la pièce. L'invention concerne en outre un procédé pour la fabrication additive d'au moins une couche d'au moins une pièce (31) et un dispositif de commande (60) pour un dispositif (30) pour la fabrication additive d'une couche d'une pièce (31) ainsi qu'un dispositif (30) pour la fabrication additive de pièces (31) à l'aide d'un tel dispositif de commande (60).
EP18800160.6A 2017-11-17 2018-11-09 Tri de bandes d'irradiation Pending EP3710183A1 (fr)

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DE102017127148.1A DE102017127148A1 (de) 2017-11-17 2017-11-17 Bestrahlungsstreifensortierung
PCT/EP2018/080770 WO2019096690A1 (fr) 2017-11-17 2018-11-09 Tri de bandes d'irradiation

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EP3710183A1 true EP3710183A1 (fr) 2020-09-23

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DE102020201450A1 (de) * 2020-02-06 2021-08-12 Siemens Aktiengesellschaft Verfahren zum Herstellen einer Stützstruktur in der additiven Herstellung, Computerprogrammprodukt und Steuerung
DE102020210681A1 (de) 2020-08-21 2022-03-10 Trumpf Laser- Und Systemtechnik Gmbh Planungseinrichtung, Fertigungseinrichtung, Verfahren und Computerprogrammprodukt zum additiven Fertigen von Bauteilen aus einem Pulvermaterial
CN117677455A (zh) * 2021-07-28 2024-03-08 Eos有限公司电镀光纤系统 用于增材构造过程的优化的过程变量值和控制数据的生成

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DE10208150B4 (de) * 2001-02-26 2009-12-17 Matthias Dr. Fockele Verfahren und Vorrichtung zur Herstellung eines Formkörpers
EP1980380A1 (fr) * 2007-04-13 2008-10-15 LBC Laser Bearbeitungs Center GmbH Dispositif de chauffage ou de refroidissement, en particulier comme partie d'un moule destiné au traitement de matières plastiques, tel qu' un moule d'injection pour plastique.
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EP3010672A2 (fr) * 2013-06-20 2016-04-27 MTU Aero Engines AG Dispositif et procédé de fabrication additive d'au moins une partie d'une pièce
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