EP4185429A1

EP4185429A1 - Manufacturing device for additive manufacturing of components from a powder material, method for changing a beam profile of an energy beam, and use of at least one acousto-optical deflector

Info

Publication number: EP4185429A1
Application number: EP21754724.9A
Authority: EP
Inventors: Matthias Allenberg-Rabe; Valentin BLICKLE; Jonas Grünewald; Philipp Wagenblast; Wilhelm Meiners
Original assignee: Trumpf Laser und Systemtechnik GmbH
Current assignee: Trumpf Laser und Systemtechnik GmbH
Priority date: 2020-07-21
Filing date: 2021-07-21
Publication date: 2023-05-31
Also published as: US20230143334A1; CN116157218A; WO2022018149A1

Abstract

The invention relates to a manufacturing device (1) for additive manufacturing of components from a powder material, comprising a beam generation device (3) designed to generate an energy beam (5), a scanner unit (7) designed to move the energy beam (5) within a working area (9) to a plurality of irradiation positions (11) to produce, by means of the energy beam (5), a component from the powder material in the working area, a deflection unit (13) designed to move the energy beam (5) in an irradiation position (11) of the plurality of irradiation positions (11) within a beam region (15) to a plurality of beam positions (17), and a control unit (19), which is operatively connected to the deflection unit (13) and is designed to control the deflection unit (13) and to change a beam profile of the beam region during manufacture of a component by changing the control of the deflection unit (13).

Description

DESCRIPTION

Manufacturing device for the additive manufacturing of components from a powder material, method for changing a beam profile of an energy beam, and use of at least one acousto-optical deflector

The invention relates to a manufacturing device for the additive manufacturing of components from a powder material, a method for changing a beam profile of an energy beam, and the use of at least one acousto-optical deflector.

When additively manufacturing components from a powder material, an energy beam is typically displaced to predetermined irradiation positions of a work area—in particular along a predetermined irradiation path—in order to locally solidify powder material arranged in the work area. In particular, this is repeated layer by layer in powder material layers arranged one after the other in the working area, in order finally to obtain a three-dimensional component made of solidified powder material. In order to increase productivity and/or to design material properties of the resulting component differently locally, it is desirable to apply different beam profiles of the energy beam to different areas within the component to be manufactured, in particular different areas within the same powder material layer in the work area. Generating suitable, adapted beam profiles by means of conventional beam shaping, in particular by means of refractive or interferometric optical elements in an optical energy beam, is often complex and cannot be used flexibly. In particular, it turns out to be difficult or even hardly possible to switch between different jet profiles during the individual production process and especially within a layer of powder material. In addition, conventional methods of beam shaping only allow the representation of a limited selection of beam profiles, so that they are also limited in their applicability.

The invention is based on the object of a manufacturing device for the additive manufacturing of components from a powder material, a method for changing a beam profile of a To create an energy beam on a work area of such a production facility, and to see the use of at least one acousto-optical deflector, the disadvantages mentioned being at least reduced, preferably avoided.

The object is achieved by providing the present technical teaching, in particular the teaching of the independent claims and the embodiments disclosed in the dependent claims and the description.

The object is achieved in particular by creating a manufacturing device for the additive manufacturing of components from a powder material, which has a beam generating device that is set up to generate an energy beam. The production device also has a scanner device that is set up to move the energy beam to a plurality of irradiation positions within a work area in order to use the energy beam to produce a component from the powder material arranged in the work area. In addition, the manufacturing device has a deflection device that is set up to shift the energy beam at one irradiation position of the plurality of irradiation positions within a beam region to a plurality of beam positions. Furthermore, the production device has a control device which is operatively connected to the deflection device and set up to control the deflection device and to change a beam profile of the beam area during the production of a component by changing the control of the deflection device.

In this way, a jet profile used can be easily and quickly specified and changed during the production of a component, particularly during the processing of the same powder material layer, without the need for special devices, in particular for generating the jet profile. In particular, it is easy and quick to switch between different beam profiles. The production device is thus very flexibly able to generate a suitable beam profile adapted to the respective locally prevailing requirements and/or conditions, in particular the respective areas of the component to be produced. It not only has high productivity, but also allows the material properties of the resulting component to be adjusted locally. In particular, this makes it possible to increase the quality of the components produced with the production device proposed here, in particular by selecting particularly suitable beam profiles. Since specially adapted to the beam profiles, in particular refractive or static interferometric optical elements can be dispensed with Manufacturing facility designed inexpensively despite their high flexibility in use, especially from the point that it requires no different devices to generate different beam profiles that cause additional parts costs, and between which would have to be switched cumbersome and time-consuming. The production facility proposed here also allows, through suitable control of the scanner device on the one hand and the deflection device on the other hand, to switch between the most efficient and, in particular, also fast component production and a particularly high-quality production, in particular also with locally varying adjustment of the material properties for the component being produced, for example a higher one Hardness in the area of the component surface than in the interior of the component.

In particular, the scanner device on the one hand and the deflection device on the other hand allow a separation of the time and length scales relevant for the production of the resulting component. While the scanner device is set up to shift the energy beam on a larger time scale than the deflection device along the plurality of irradiation positions, in particular along a predetermined radiation path, more or less globally over the entire working area, the deflection device is set up to move the energy beam on a relative to the time scale of the scanner device shorter time scale quasi locally at an irradiation position predetermined by the scanner device and quasi fixed due to the time scale separation to the plurality of beam positions within the beam area. As a result of the time scale separation, a specific beam profile as a geometric shape and as an intensity profile of the beam area arises quasi-statically at each irradiation position of the plurality of irradiation positions. In turn, the scanner device in particular shifts the beam profile generated in this way along the plurality of irradiation positions, in particular along the irradiation path. By changing the control of the deflection device, the beam profile of the beam area, in particular the shape of the beam area and/or the intensity profile in the beam area, can now advantageously be changed as desired, if necessary even from irradiation position to irradiation position. As a rule, however, a plurality of adjacent irradiation positions, in particular a contiguous section of the irradiation path, are covered with the same beam profile. However, different sections of the irradiation path are preferably covered with different beam profiles. The generated beam profile is in particular also quasi-static with regard to the melting process in the powder material, the time scale for the deflection of the energy beam by the deflection device being significantly shorter than the characteristic interaction time of the energy beam with the powder material. Averaged over time, the dynamically generated beam profile interacts with the powder material like a statically generated profile.

Additive or generative production of a component is understood in particular as meaning a layered construction of a component from powder material, in particular a powder bed-based method for producing a component in a powder bed, in particular a production method which is selected from a group consisting of selective laser sintering, Laser Metal Fusion (LMF), Direct Metal Laser Melting (DMLM), Laser Net Shaping Manufacturing (LNSM), and Laser Engineered Net Shaping (LENS). The production facility is therefore set up in particular to carry out at least one of the aforementioned additive or generative production processes.

An energy beam is generally understood to mean directed radiation that can transport energy. This can generally involve particle radiation or wave radiation. In particular, the energy beam propagates through the physical space along a propagation direction and thereby transports energy along its propagation direction. In particular, it is possible by means of the energy beam to deposit energy locally in the work area.

In a preferred embodiment, the energy beam is an optical working beam. An optical working beam is to be understood in particular as directed electromagnetic radiation, continuous or pulsed, which is suitable in terms of its wavelength or a wavelength range for the additive or generative manufacturing of a component from powder material, in particular for sintering or melting the powder material. In particular, an optical working beam means a laser beam that can be generated continuously or in a pulsed manner. The optical working beam preferably has a wavelength or a wavelength range in the visible electromagnetic spectrum or in the infrared electromagnetic spectrum, or in the overlap region between the infrared range and the visible range of the electromagnetic spectrum. A working area is understood to mean in particular an area, in particular a plane or surface, in which the powder material is arranged and which is locally impinged on by the energy beam in order to locally solidify the powder material. In particular, the powder material is sequentially arranged in layers in the work area and is locally exposed to the energy beam in order to produce a component—layer by layer.

An irradiation position is understood to mean, in particular, a location within the work area at which energy is deposited locally by means of the energy beam in the work area, in particular in the powder material arranged there. The scanner device is preferably set up to displace the energy beam within the working area along an irradiation path, the irradiation path consisting of a time sequence of irradiation positions swept over one after the other by the energy beam. The individual irradiation positions can be arranged at a distance from one another, but they can also overlap one another. In particular, the irradiation path can be a path continuously scanned with the energy beam.

A beam area is understood here in particular as an area at an irradiation position within which the specific intensity profile is generated. In this case, the beam area has, in particular, a surface area that is larger than a cross section of the energy beam projected onto the work area.

The deflection device is thus set up in particular to shift the energy beam at a fixed irradiation position, in particular at each irradiation position, within the beam area and thus to impinge on a specific area - the beam area - within the working area with the energy beam, which is larger, at the fixed irradiation position as the cross-section of the energy beam projected onto the work area; in contrast, the scanner device is set up to shift the energy beam between the individual irradiation positions and thus in turn to enable the deflection device to scan a new beam area at a different location with the energy beam. The deflection device is therefore used for local deflection of the energy beam at an irradiation position, while the scanner device is used for global displacement of the energy beam on the work area.

The scanner device and the deflection device thus differ in particular - as already stated - with a view to the length scale of the possible displacement, the scanner device is preferably set up to cover the entire work area with the energy beam, the deflection device being set up to deflect the energy beam locally at an irradiation position within the beam area specified by the scanner device, with the respective beam area being very much smaller than the work area. In particular, the beam area preferably has a length scale in the range from a few (i.e. less than ten) millimeters to a few centimeters, and preferably an areal extent in the range from a few square millimeters to a few square centimeters, while the working area has a length scale in the range from a few decimeters to has to a few meters, and preferably an areal extent in the range of a few square decimeters to a few square meters.

The scanner device on the one hand and the deflection device on the other hand preferably also differ with regard to the time scale on which the energy beam is deflected: In particular, the deflection of the energy beam by the deflection device within the beam area preferably takes place on a shorter, in particular much shorter time scale than the deflection within the Working area by the scanner device, that is, as the change from one irradiation position to the next irradiation position. In this way, a specific beam profile can advantageously be generated quasi-statically at each irradiation position, which is predetermined by a momentary setting of the scanner device, by means of the deflection device by suitably shifting the energy beam within the beam area. Preferably, the time scale over which the energy beam can be deflected by the deflection means is less than the time scale over which deflection of the energy beam can occur by a factor of 10 to 1000, preferably 20 to 200, preferably 40 to 100, or more done by the scanner device.

The control device is preferably selected from a group consisting of a computer, in particular a personal computer (PC), a plug-in card or control card, and an FPGA board. In a preferred embodiment, the control device is an RTC6 control card from SCANLAB GmbH, in particular in the version currently available on the date determining the seniority of the present property right.

The control device is preferably set up to synchronize the scanner device with the deflection device using a digital RF synthesizer, the RF synthesizer being controlled via a programmable FPGA board. In addition, a division into the comparatively slow movement of the scanner device and the rapid movement of the deflection device by means of a crossover. Position values and default values for the beam profile are preferably calculated, which are then converted in the FPGA board into time-synchronous frequency defaults for the RF synthesizer. Before that, the beam profiles need to be spatially assigned to the irradiation positions in the respective powder material layer, which is preferably already carried out in a build processor. This writes the corresponding data to a file, which is then preferably used by the control device. Alternatively or additionally, it is preferably possible to select from predefined beam profiles.

According to a development of the invention, it is provided that the deflection device is set up to suddenly shift the energy beam to the plurality of beam positions, with the plurality of beam positions being discrete beam positions. In particular, it is possible for adjacent beam positions to be spaced apart from one another. However, it is also possible for adjacent beam positions to overlap with one another at least in regions. The energy beam is advantageously not shifted continuously from beam position to beam position by the deflection device, but in particular in discrete steps. Without restriction and without wanting to be bound to theory, it can be assumed for all practical purposes that the energy beam disappears at the first beam position and appears at the second beam position during the abrupt or discrete shift from a first beam position to a second beam position, especially without sweeping over intermediate areas. In this way, a very rapid displacement of the energy beam within the beam area is possible, and material transport processes that would otherwise be based on a continuous displacement of the energy beam can preferably be avoided, which increases the quality of the resulting component.

According to one development of the invention, it is provided that the control device is set up to change a shape of the beam area as a beam profile during the production of the component. A shape of the beam area is understood to mean in particular the geometry of an outer border of the beam area or--equivalently--a shape of the surface over which the energy beam sweeps quasi-statically within the beam area. This corresponds to a quasi-static cross-sectional profile of the energy radiation with which the working area is exposed at the respective irradiation position.

Alternatively or additionally, the control device is preferably set up to change an intensity profile in the beam area as the beam profile during the production of the component. Under In this context, an intensity profile is understood to mean, in particular, a surface power density distribution of the energy beam.

By changing the beam profile, in particular the shape of the beam area and/or the intensity profile, it is advantageously possible to adapt the beam profile quickly and easily as required during the manufacture of the component.

According to a development of the invention, it is provided that the control device is set up to specify the blasting profile, in particular the shape of the blasting area, depending on a current irradiation position within the component to be produced, in particular within the same powder material layer. In particular, the control device is set up to specify different beam profiles at different irradiation positions. In this way, the beam profile can advantageously be adapted flexibly and locally to different conditions or requirements.

For example, a different beam profile can be selected for an outer enveloping area of the resulting component, that is to say in particular for its surface, than for an inner area within the outer enveloping area of the component.

Alternatively or additionally, a different jet profile can be selected for a contour, i.e. a border or outer boundary of an area to be solidified or solidified within a powder material layer, than for a so-called core, i.e. an area within the contour in the powder material layer.

Additionally or alternatively, yet another jet profile can be selected for an overhang area, an overhang area being an area within a powder material layer below which, ie in underlying powder material layers, non-solidified powder material is located. Such an overhang is also referred to as "down skin". This term also refers to the bottom layer of powder material comprising solidified powder material, i.e. a bottom surface of the component.

Additionally or alternatively, yet another jet profile can be used for a cover layer region, with a cover layer region being a region within a powder material layer above which, ie in overlying powder material layers, non-solidified powder material is located. Such a Top layer area is also referred to as "up skin". This term also refers to the uppermost layer of powder material, which still comprises solidified powder material, ie a roof surface or uppermost surface of the component.

In particular, another beam profile can be selected for a volume area of the component being produced, i.e. an area within a powder material layer that is surrounded on all sides, in particular within the powder material layer, but also above and below the powder material layer just processed, in the finished component by solidified powder material . Such an area is also referred to as an “in skin” area.

Different beam profiles can also be used on the one hand for filigree structures of a component, which are, for example, in the order of magnitude of the beam area, and on the other hand for coarser, larger, in particular flat structures. If necessary, filigree structures, in particular closed structural sections, can also be generated solely by controlling the deflection device and generating a local beam profile at a fixed irradiation position, without the scanner device being controlled, in particular by suitably controlling the deflection device to create a beam profile in the shape of the one to be trained Structure section is generated.

The specification of the beam profile depending on the current irradiation position also makes it possible to influence the resulting component structure via the intensity distribution. For example, a grain structure of the resulting component changes during irradiation with changed temperature gradients and solidification conditions. Thus, in particular, local strength values or surface hardnesses can also be influenced and, in particular, varied locally.

In particular, it is possible to harden the outer surface of the component by producing a higher hardness of the solidified powder material in several powder material layers arranged directly below or above in up skin or down skin areas. Correspondingly, contour lines can also be hardened to a greater extent with greater hardness in individual powder material layers.

In contrast, an outer enveloping area is in particular an area within a powder material layer which has at least one boundary line to non-solidified powder material within the powder material layer. Such an envelope area can also be an overhang but it can also be surrounded by solidified powder material in the finished component above and below the currently produced layer of powder material.

According to a development of the invention, it is provided that the control device is set up to specify the shape of the beam area as a shape that is selected from a group consisting of: A rotationally symmetrical shape, in particular a three-fold rotationally symmetrical or higher-fold rotationally symmetrical shape, in particular a C ₃ rotationally symmetrical shape, a circular shape, a ring shape, a torus shape or donut shape, a polygon, a rectangle, an elongated shape, preferably with rounded corners, a line shape, an irregular shape, and a point shape. Larger, more extensive molds are preferably used in order to produce internal skin areas and/or core areas and/or inner areas of the component quickly and thus with high productivity, with more filigree, smaller molds being preferably used, in particular for filigree or detailed enveloping areas or edit overhangs.

The control device is preferably set up to change or switch over between at least two different shapes of the beam area.

According to one development of the invention, it is provided that the control device is set up to generate the intensity profile as a Gaussian intensity profile. In particular, this can also be a Gaussian profile that is elongated along a direction within the working area, with the axis of the longest extension of the Gaussian profile in a preferred embodiment being perpendicular to an irradiation path, i.e. a particularly local displacement direction of the energy beam in the working area, or alternatively along the Irradiation path of the energy beam, ie in the displacement direction, can extend. However, it is of course also possible for the axis of the longest extension of the Gaussian profile to extend at an angle to the irradiation path.

Alternatively, the control device is preferably set up to generate the intensity profile as a non-Gaussian intensity profile.

Alternatively or additionally, the control device is set up to generate the intensity profile as a constant intensity profile, in particular in the manner of a flat-top beam. Alternatively or additionally, the control device is set up to generate the intensity profile as an asymmetrical or distorted intensity profile. The control device is thus preferably able to generate a large number of different intensity profiles, in particular any intensity profiles, and to switch between them.

According to a development of the invention, it is provided that the control device is set up to specify the blasting profile, in particular the shape of the blasting area, depending on a current irradiation position within the component to be produced, in particular within the same powder material layer, in such a way that the blasting profile projected onto the working area corresponds to a predetermined projected beam profile.

This solves the problem of the beam profile being distorted when the powder material is not perpendicular to the working area. For example, a circular beam profile that is incident on the powder material at an angle to the surface normal of the powder material in the working area is distorted into an ellipse. Correspondingly, an ellipse can be specified for the beam profile in such a way that the beam profile projected onto the powder material is again circular.

In a preferred development, the control device is set up to distort the specified beam profile in such a way that the projected beam profile corresponds to one of the beam profiles mentioned in the previous developments.

According to a development of the invention, it is provided that the deflection device is arranged in front of the scanner device in the direction of propagation of the energy beam. The propagation direction of the energy beam is in particular a propagation direction of the energy radiation in space. The term “before” refers to the deflection device being reached first by the energy beam during the propagation of the energy beam along the direction of propagation, with the scanner device being reached by the energy beam thereafter. The arrangement of the deflection device in the direction of propagation in front of the scanner device represents a particularly suitable configuration for flexible generation of the beam profile.

According to a development of the invention, it is provided that the deflection device has at least one acousto-optical deflector. An acousto-optical deflector is understood to mean, in particular, an element which has a solid body which is transparent to the energy beam and to which sound waves, in particular ultrasonic waves, can be applied, with the energy beam passing through the transparent solid body depending on the frequency of the sound waves with which the transparent solid is applied, is deflected. In this case, in particular an optical lattice is generated in the transparent solid by the sound waves. Such acousto-optical deflectors are advantageously able to deflect the energy beam very quickly by an angular range predetermined by the frequency of the sound waves generated in the transparent solid. In particular, switching speeds of up to 1 MHz can be achieved. In particular, the switching times for such an acousto-optical deflector are significantly faster than typical switching times for conventional scanner optics, in particular galvanometer scanners, which are generally used to move an energy beam within a work area of a manufacturing facility of the type discussed here. Therefore, such an acousto-optical deflector can be used in a particularly suitable manner to generate a quasi-static beam profile in the beam area.

Modern acousto-optical deflectors deflect the energy beam with an efficiency of at least 90% into a predetermined angular range of the first diffraction order, so that they are excellently suited as a deflection device for the production device proposed here. The material used, which is transparent to the energy beam, and a suitably high intensity of the coupled ultrasonic waves are particularly decisive for the high efficiency.

In a preferred embodiment, the deflection device has two acousto-optical deflectors that are not oriented parallel to one another, but are preferably oriented perpendicularly to one another. A deflection of the energy beam in two directions that are not parallel to one another, in particular perpendicular to one another, is thus advantageously possible. The acousto-optical deflectors, which are not parallel to one another, are preferably arranged one behind the other in the direction of propagation of the energy beam.

“Behind” here means in particular that an element arranged behind another element is reached by the energy beam when the energy beam propagates along the propagation direction after the other element, analogously to the definition given above for “in front of”. According to a development of the invention, it is provided that the production device has a separating mirror in the propagation direction of the energy beam behind the deflection device and in front of the scanner device, which is set up to separate a zeroth-order partial beam of the energy beam from a first-order partial beam. In particular, if the deflection device has an acousto-optical deflector, due to its configuration, analogous to an optical grating, it generates an undiffracted partial beam of the zeroth order and a diffracted or deflected partial beam of the first order. Only the first-order partial beam should be used to irradiate the working area. With the aid of the separating mirror, it is now advantageously possible to separate the partial beams of different orders from one another and only allow the first-order partial beam to pass through to the work area, in particular to the scanner device. The partial beam of the zeroth order is preferably deflected by the separating mirror into a beam trap.

This representation is correct for the use of exactly one acousto-optical deflector. If, in a preferred embodiment, two acousto-optical deflectors are used that are not oriented parallel to one another, but are preferably oriented perpendicularly to one another, then the corresponding orders of diffraction must also be considered cumulatively: the partial beam should ultimately be used as the effective beam, which was initially used as a first-order partial beam of the first acousto-optical deflector see deflector hits the second acousto-optical deflector, and then in turn is diffracted as a first-order partial beam from the second acousto-optical deflector. In this case, the useful beam as a “first-order partial beam” is more or less a first-order partial beam. In order to keep the presentation simple, only the first order will be used in the following.

In particular, the separating mirror preferably has a through hole in a surface that reflects the energy beam, through which the first-order partial beam passes the separating mirror to the work area, in particular to the scanner device. The partial beam of the zeroth order--and preferably also undesired partial beams of a higher order than the first order--impact on the reflecting surface and are deflected by the separating mirror into the beam trap.

The separation mirror is preferably arranged in the vicinity of an intermediate focus of a telescope. This enables a particularly clean separation of the partial beams of different orders. The separation mirror is preferably not arranged exactly in the intermediate focus of the telescope, in particular in order to avoid damage to the separation mirror due to an excessive power density of the energy beam.

The separation mirror is preferably arranged offset at a distance of one fifth of the focal length of the telescope from the intermediate focus along the direction of propagation, preferably in front of the intermediate focus in the direction of propagation. At the same time, this ensures, on the one hand, a clean separation of the different partial beams of different orders and, on the other hand, a sufficiently low power density of the energy beam on the separation mirror in order to avoid damage to it by the energy beam.

The telescope is preferably a 1:1 telescope, ie in particular it has neither a beam-reducing nor a beam-enlarging property. In particular, the telescope fulfills two tasks, namely, in addition to the separation of the different partial beams of different orders, it is also preferable to image a beam rotation point, also referred to as a pivot point, to a point in the propagation direction behind the telescope, with the imaged beam rotation point preferably being either on a pivot point of the subsequent scanner device or on a point with the smallest aperture.

Strictly speaking, this consideration also applies only to the use of a single acousto-optical deflector. If two acousto-optical deflectors which are not oriented parallel to one another, but are preferably oriented perpendicularly to one another, are used, two beam pivot points result, namely one beam pivot point in each acousto-optical deflector. However, if the two acousto-optical deflectors are arranged as close as possible one behind the other in the direction of propagation, a single imaginary common beam pivot point can be assumed as a good approximation, which is then arranged between the acousto-optical deflectors.

In a development of the invention, it is provided that the deflection device has at least one electro-optical deflector, preferably two electro-optical deflectors that are not oriented parallel, in particular perpendicular to one another. Electro-optical deflectors (EOD) deflection is based on refraction upon passage of an optically transparent material. With one or two EODs, the aforementioned exemplary embodiments can be modified with acousto-optical deflectors by replacing one or two of the acousto-optical deflectors with an EOD. According to a development of the invention, it is provided that the scanner device has at least one scanner, in particular a galvanometer scanner, piezo scanner, polygon scanner, MEMS scanner, and/or a working head or processing head that can be displaced relative to the work area. The scanner devices proposed here are particularly suitable for shifting the energy beam within the working area between a plurality of irradiation positions.

A working head or processing head that can be displaced relative to the work area is understood here in particular to mean an integrated component of the production facility which has at least one radiation outlet for at least one energy beam, the integrated component, i.e. the working head, as a whole along at least one displacement direction, preferably along two mutually perpendicular directions of displacement, is displaceable relative to the work area. Such a working head can, in particular, be designed in the form of a portal or be guided by a robot. In particular, the working head can be designed as a robot hand of a robot.

According to a development of the invention, it is provided that the beam generating device is designed as a laser. The energy beam is thus advantageously generated as an intensive beam of coherent electromagnetic radiation, in particular coherent light.

According to a development of the invention, it is provided that the production device is set up for selective laser sintering. Alternatively or additionally, the production facility is set up for selective laser melting. These configurations of the production facility have proven to be particularly advantageous.

The object is also achieved by creating a method for changing a beam profile of an energy beam on a work area of a production facility during the additive manufacturing of a component from a powder material, the energy beam being shifted to a plurality of irradiation positions within the work area in order to use the energy beam to produce the component from the powder material arranged in the work area. The energy beam is shifted to a plurality of beam positions at at least one irradiation position of the plurality of irradiation positions within a beam area. The beam profile is changed by changing the displacement of the energy beam in the beam area. In connection with the method, there are in particular the advantages that have already been explained in connection with the production facility. According to a development of the invention, it is provided that the beam profile, in particular the shape of the beam area, is changed depending on a current irradiation position within the component to be produced, in particular within the same powder material layer, with different beam profiles being generated in particular at different irradiation positions.

According to a development of the invention, it is provided that the beam profile, in particular the shape of the beam area, is changed depending on a current irradiation position within the component to be produced, in particular within the same powder material layer, in such a way that the beam profile projected onto the working area corresponds to a predetermined projected beam profile . The same advantages result in connection with this method as have already been explained in connection with the production facility.

Finally, the object is also achieved by specifying the use of at least one acousto-optical deflector, the acousto-optical deflector for changing a beam profile of an energy beam on a work area a production device during the additive manufacturing of a component from a powder material, in particular within the same powder material layer, is used. In connection with the use of the acousto-optical deflector, there are in particular those advantages which have already been explained in connection with the production facility and the method.

In a preferred embodiment, the acousto-optical deflector is used in a method according to the invention for changing a beam profile of an energy beam or in one of the previously described preferred embodiments of such a method.

The acousto-optical deflector is preferably used in a production facility according to the invention or in a production facility according to one of the previously described exemplary embodiments of such a production facility.

According to a further development of the invention, it is provided that two acousto-optical deflectors, which are in particular not oriented parallel to one another but are preferably oriented perpendicularly to one another, are used in order to change the beam profile of the energy beam. It is thus possible in a particularly simple and rapid manner to change the beam profile in two directions which are preferably not oriented parallel to one another, but are preferably in particular perpendicular to one another. The invention is explained in more detail below with reference to the drawing. show:

Figure 1 shows a representation of an embodiment of a manufacturing device for the additive manufacturing of components from a powder material,

Figure 2 is a schematic representation of a plurality of different forms of a

beam area, and

Figure 3 is a sketch to explain an electro-optical deflection in the generative

Production.

1 shows a schematic representation of an exemplary embodiment of a manufacturing device 1 that is set up for the additive manufacturing of components from a powder material. The production facility 1 has a beam generating device 3 which is set up to generate an energy beam 5. The production facility 1 also has a scanner device 7 which is set up to move the energy beam 5 to a plurality of irradiation positions 11 within a work area 9 in order to to produce a component from the powder material arranged in the work area 9 by means of the energy beam 5 .

The production device 1 has a deflection device 13 which is set up to shift the energy beam 5 at an irradiation position 11 of the plurality of irradiation positions 11 within a beam region 15 to a plurality of beam positions 17 .

The production device 1 has a control device 19, which is operatively connected to the deflection device 13 and set up to control the deflection device 13 and to change a beam profile of the beam area 15 during the production of the component by changing the control of the deflection device 13.

In this way, it is possible in a simple and extremely flexible manner to easily and quickly specify and change a jet profile used during the production of the component, in particular during the processing of the same powder material layer, without it being necessary to do this in particular, in particular for the generation of the jet profile specific facilities required. In particular, it is easy and quick to switch between different beam profiles. The deflection device 13 is set up, in particular, to suddenly shift the energy beam 5 to the plurality of beam positions 17 , the beam positions 17 being discrete beam positions 17 .

The control device 19 is set up in particular to change a shape of the beam area 15 and/or an intensity profile in the beam area 15 as a beam profile during the production of the component.

The control device 19 is set up in particular to specify the beam profile, in particular the shape of the beam region 15, as a function of a current irradiation position 11 within the component to be produced. In a preferred embodiment, the control device 19 is set up to specify different beam profiles at different irradiation positions 11 . In particular, this can be carried out within the same powder material layer, for example in order to apply different jet profiles to different areas of the powder material layer, in particular an enveloping area on the one hand and an inner area on the other. Alternatively or additionally, the beam profile can be selected depending on whether a contour, a core, an overhang area, a cover layer area, or a volume area of the resulting component is being processed.

The control device 19 is preferably set up to specify the shape of the beam region 15 as a shape that is selected from a group consisting of: a rotationally symmetrical shape, in particular a threefold rotationally symmetrical or higher rotationally symmetrical shape, a circular shape, a ring shape, a torus shape or donut shape, a polygon, a rectangle, an elongated shape preferably with rounded corners, a line shape, an irregular shape, and a dot shape. In particular, the control device 19 is set up to change or switch over between different shapes of the beam area 15 .

The control device 19 is set up in particular to generate the intensity profile as a Gaussian, non-Gaussian, constant, asymmetrical or distorted intensity profile.

The deflection device 13 is arranged in front of the scanner device 7 in particular in the direction of propagation of the energy beam 5 . The deflection device 13 has in particular at least one acousto-optical deflector 21, here in particular two acousto-optical deflectors 21 not oriented parallel, in particular perpendicular to one another, namely a first acousto-optical deflector 21.1 and a second acousto-optical deflector 21.2. The acousto-optical deflectors 21, which are oriented perpendicularly to one another, allow the energy beam 5 to be deflected in two mutually perpendicular directions and thus in particular to scan the entire surface of the beam region 15.

The production device 1 also has a separating mirror 23 behind the deflection device 13 and in front of the scanner device 7 in the propagation direction of the energy beam 5 , which is set up to separate a zero-order partial beam from a first-order partial beam of the energy beam 5 . For this purpose, the separation mirror 23 has in particular a through hole 25 which is provided in a surface 27 of the separation mirror 23 which reflects the energy beam 5 and which completely penetrates the separation mirror 23 . The first-order partial beam, which is to be forwarded in the desired manner to the scanner device 7, is guided through the through hole 25 and thus finally reaches the scanner device 7. The undesired zero-order partial beam, and possibly also undesired higher-order partial beams, on the other hand, hit the reflecting surface 27 and are deflected to a beam trap 29.

The separation mirror 23 is arranged in particular in the vicinity of an intermediate focus 31 of a telescope 33, in particular not exactly in a plane of the intermediate focus 31, particularly preferably offset at a distance of one-fifth of the focal length of the telescope 33 along the propagation direction, in particular in front of the intermediate focus 31. This advantageously prevents the reflective surface 27 from being exposed to an excessively high power density of the energy beam 5 .

The telescope 33 preferably has a first lens 35 and a second lens 37 . It is preferably designed as a 1:1 telescope. The telescope 33 preferably has a focal length of 500 mm.

The mode of operation of the telescope 33 is preferably twofold: on the one hand, the telescope 33 enables a particularly advantageous and clean separation of the different orders of the energy beam 5 deflected by the deflection device 13, particularly with the arrangement of the separation mirror 23 chosen here; on the other hand, the telescope forms 33 preferably an imaginary common beam pivot point 39 of the deflection device 13 advantageously to a pivot point 41 of the scanner device 7 .

Alternatively, the telescope 33 preferably maps the beam pivot point 39 to a point of smallest aperture.

In order to enable a compact arrangement of the production device 1, the energy beam 5 is preferably deflected several times by deflection mirrors 43.

The scanner device 7 preferably has at least one scanner, in particular a galvanometer scanner, piezo scanner, polygon scanner, MEMS scanner and/or working head.

The beam generating device 3 is preferably designed as a laser.

The production device 1 is preferably set up for selective laser sintering and/or for selective laser melting.

As part of a method for changing a beam profile of an energy beam 5 on a work area 9 of a production facility 1 during the additive manufacturing of a component from a powder material, the energy beam 5 is preferably displaced within the work area 9 to a plurality of irradiation positions 11 in order to use the energy beam 5 to Produce component from the arranged in the work area 9 powder material. The energy beam 5 is shifted to a plurality of beam positions 17 at at least one irradiation position 11 of the plurality of irradiation positions 11 within a beam region 15 . The beam profile is changed by changing the displacement of the energy beam 5 in the beam area 15 .

The beam profile, in particular the shape of the beam area 15, is preferably changed depending on a current irradiation position 11 within the component to be produced, in particular within the same powder material layer, with different beam profiles being generated in particular at different irradiation positions 11.

When at least one acousto-optical deflector 21 is used, it is used to change a beam profile of an energy beam 5 on a work area 9 of a manufacturing device 1 during the additive manufacturing of a component from a powder material. Preferably, two acousto-optical deflectors 21.1, 21.2 oriented in particular not parallel, in particular perpendicular to one another, are used.

Fig. 2 shows a schematic representation of a plurality of shapes of the beam region 15.

A first, circular shape 51 for the beam area 15 is shown at a).

At b) a second, polygonal, here in particular hexagonal shape 53 for the beam area 15 is shown.

At c) a third, rectangular shape 55 for the beam area 15 is shown.

At d) a fourth, elongated shape 57 for the beam area 15 is shown with rounded ends.

Finally, at e) a fifth, ring-shaped, toroidal or donut-shaped shape 59 for the beam area 15 is shown.

3 schematically shows an adjustable deflection of the energy beam 5 with an EOD 131, the refractive index or a refractive index gradient of the optically transparent material of the EOD 131 being adjustable by applying a voltage. Depending on the voltage applied, the deflection of a laser beam 133 varies, which is preferably again incident on the EOD 131 at the Brewster angle and emerges from it at a correspondingly adjustable deflection angle. A laser beam 133A deflected in this way could be supplied to the scanner device 7 in the arrangement of FIG. A voltage source 135 enables precise adjustment of the voltage that is present between the top and bottom of the prism-shaped crystal forming the EOD 131, for example in FIG. Depending on the set voltage, the refractive index or the refractive index gradient and thus the deflection of the energy beam 5 can be set. With regard to the refraction behavior present at the EOD, reference is also made to "Electro-optic and acousto-optic laser beam scanners"; Romans G.R.B.E. et al., Physics Procedia 56 (2014) 29-39.

Claims

EXPECTATIONS

1. Manufacturing device (1) for the additive manufacturing of components from a powder material, with a beam generating device (3) which is set up for generating an energy beam (5), a scanner device (7) which is set up to the energy beam (5) inside a work area (9) to a plurality of irradiation positions (11) in order to use the energy beam (5) to produce a component from the powder material arranged in the work area (9), a deflection device (13) which is set up to deflect the energy beam (5) to shift at one irradiation position (11) of the plurality of irradiation positions (11) within a beam region (15) to a plurality of beam positions (17), and with a control device (19) which is operatively connected to the deflection device (13) and is set up to control the deflection device (13), and to change a beam profile of the beam area during the manufacture of a component by the Control of the deflection device (13) is changed.

2. Manufacturing device (1) according to claim 1, wherein the deflection device (13) is set up to suddenly shift the energy beam (5) to the plurality of discrete beam positions (17).

3. Production device (1) according to one of the preceding claims, wherein the control device (19) is set up to change a shape of the beam area (15) and/or an intensity profile in the beam area (15) as a beam profile during production of the component.

4. Production device (1) according to one of the preceding claims, wherein the control device (19) is set up to determine the beam profile, in particular the shape of the beam area (15), depending on a current irradiation position (11) within the component to be produced, in particular within the same powder material layer, in particular in order to specify different beam profiles at different irradiation positions (11).

5. Manufacturing device (1) according to one of the preceding claims, wherein the control device (19) is set up to specify the shape of the beam area (15) as a shape that is selected from a group consisting of: a rotationally symmetrical shape, in particular one threefold rotationally symmetrical or higher rotationally symmetrical shape, a circular shape, a ring shape, a torus shape or donut shape, a polygon, a rectangle, an elongated shape, preferably with rounded corners, a line shape, an irregular shape, and a point shape.

6. Manufacturing device (1) according to any one of the preceding claims, wherein the

Control device (19) is set up to generate the intensity profile as a Gaussian, non-Gaussian, constant, asymmetrical or distorted intensity profile.

7. Manufacturing device (1) according to any one of the preceding claims, wherein the

Control device (19) is set up to specify the blasting profile, in particular the shape of the blasting area (15), depending on a current irradiation position (11) within the component to be produced, in particular within the same powder material layer, in such a way that the working area (9) projected beam profile corresponds to a predetermined projected beam profile.

8. Manufacturing device (1) according to any one of the preceding claims, wherein the

Deflection device (13) is arranged in the propagation direction of the energy beam (5) in front of the scanner device (7).

9. Manufacturing device (1) according to any one of the preceding claims, wherein the

Deflection device (13) has at least one acousto-optical deflector (21), preferably two acousto-optical deflectors (21) oriented non-parallel, in particular perpendicular to one another.

10. Manufacturing device (1) according to any one of the preceding claims, wherein the deflection device (13) has at least one electro-optical deflector (21), preferably two electro-optical deflectors (21) oriented non-parallel, in particular perpendicular to one another.

11. Manufacturing device (1) according to any one of the preceding claims, wherein the

Scanner device (7) has at least one scanner, in particular a galvanometer scanner, piezo scanner, polygon scanner, MEMS scanner, and/or a work head that can be displaced relative to the work area (9).

12. Manufacturing device (1) according to any one of the preceding claims, wherein the

Beam generating device (3) is designed as a laser.

13. Manufacturing device (1) according to any one of the preceding claims, wherein the

Production device (1) is set up for selective laser sintering and/or for selective laser melting.

14. A method for changing a beam profile of an energy beam (5) on a work area (9) of a production device (1) during the additive manufacturing of a component from a powder material, the energy beam (5) within the work area (9) at a plurality of irradiation positions (11) in order to produce the component from the powder material arranged in the work area (9) by means of the energy beam (5), the energy beam (5) being at at least one irradiation position (11) of the plurality of irradiation positions (11) within a beam area (15) is relocated to a plurality of beam positions (17), and wherein the beam profile is changed by changing the displacement of the energy beam (5) in the beam region (15).

15. The method according to claim 14, wherein the beam profile, in particular the shape of the beam area (15), is changed as a function of a current irradiation position (11) within the component to be produced, in particular within the same powder material layer, with in particular at different irradiation positions (11) different beam profiles can be generated.

16. The method according to claim 14 or 15, wherein the beam profile, in particular the shape of the beam area (15), depending on a current irradiation position (11) within the component to be produced, in particular within the same powder material layer, such is changed so that the beam profile projected on the working area (9) corresponds to a predetermined projected beam profile.

17. Use of at least one acousto-optical deflector (21) for changing a beam profile of an energy beam (5) on a work area (9) of a manufacturing device (1) during the additive manufacturing of a component from a powder material.

18. Use according to claim 17, wherein two acousto-optical deflectors (21.1, 21.2) oriented non-parallel, in particular perpendicular to one another, are used.