WO2024063641A1 - An apparatus for producing an object by powder bed additive manufacturing and a method of calibrating the apparatus - Google Patents

An apparatus for producing an object by powder bed additive manufacturing and a method of calibrating the apparatus Download PDF

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Publication number
WO2024063641A1
WO2024063641A1 PCT/NL2023/050472 NL2023050472W WO2024063641A1 WO 2024063641 A1 WO2024063641 A1 WO 2024063641A1 NL 2023050472 W NL2023050472 W NL 2023050472W WO 2024063641 A1 WO2024063641 A1 WO 2024063641A1
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WO
WIPO (PCT)
Prior art keywords
electromagnetic radiation
powdered material
bath
surface level
unit
Prior art date
Application number
PCT/NL2023/050472
Other languages
French (fr)
Inventor
Mark Herman Else Vaes
Adrie BOVERHOF
Original Assignee
Additive Industries B.V.
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 Additive Industries B.V. filed Critical Additive Industries B.V.
Publication of WO2024063641A1 publication Critical patent/WO2024063641A1/en

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Classifications

    • 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
    • B22F10/31—Calibration of process steps or apparatus settings, e.g. before or during 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
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B22F12/45—Two or more
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • 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
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • 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

Definitions

  • the present disclosure relates to an apparatus for producing an object by means of additive manufacturing, the apparatus comprising: a process chamber for receiving a bath of powdered material to produce the object; a support for positioning the object in relation to a surface level of the bath of powdered material; a solidifying device arranged for emitting a beam of electromagnetic radiation for melting a selective layer-part of the powdered material of the bath of powdered material; a scanner device arranged for moving the beam of electromagnetic radiation along the surface level of the bath of powdered material.
  • the present disclosure relates to a method of calibrating an apparatus according to the first aspect of the present disclosure.
  • 3D printing or additive manufacturing refers to any of various processes for manufacturing a three-dimensional object in which material is joined or solidified under computer control to create a three-dimensional object, with material being added together, typically layer by layer.
  • the apparatus comprises: an emitter unit arranged for emitting further electromagnetic radiation, preferably a beam of further electromagnetic radiation, on the surface level of the bath of powdered material or the support; a detection unit arranged for detecting a position of the further electromagnetic radiation, preferably the beam of further electromagnetic radiation, at the surface level of the bath of powdered material or the support via the scanner device or arranged such that an optical path of the further electromagnetic radiation, preferably the beam of further electromagnetic radiation, between the bath of powdered material or the support and the detection unit, bypasses the scanner device for detecting the position of the further electromagnetic radiation, preferably the beam of further electromagnetic radiation, at the surface level of the bath of powdered material or the support.
  • the present disclosure relies at least partly on the insight that for the manufacturing of three-dimensional objects, in particular in additive manufacturing of metal objects, the manufacturing of the object may require the apparatus for manufacturing the object to run for a relative long time period. During this period it is beneficial if the beam of electromagnetic radiation for melting a selective layer-part of the powdered material of the bath of powdered material is moved such that it operates within a defined accuracy of a defined coordinate system. If the apparatus or a component thereof such as the scanner device, the process chamber and/or the solidifying device drift during the period of manufacturing relative to the defined coordinate system the geometrical accuracy of the object may be negatively affected.
  • drift may relate a uniform drift of the beam of electromagnetic radiation along the surface level of the bath of powdered material relative to the defined coordinate system or a reference coordinate system relating to a corresponding position of the beam of electromagnetic radiation at a previous instance, such as before the start of the manufacturing of the object or during manufacturing of the object.
  • This uniform drift may be due to a drift of the scanner device and/or the solidifying device that is independent on the position of the beam of electromagnetic radiation at the surface level.
  • the uniform drift causes a shift that is equal at the whole surface level.
  • the drift within the context of the present disclosure may also relate to a position dependent drift that is dependent on the position of the beam of electromagnetic radiation along the surface level of the bath of powdered material relative to the defined coordinate system or the reference coordinate system relating to the corresponding position of the beam of electromagnetic radiation at the previous instance, such as before the start of the manufacturing of the object or during manufacturing of the object.
  • This position dependent drift may due to a drift of the scanner device that is dependent on the position of the beam of electromagnetic radiation at the surface level. In other words, the position dependent drift causes a shift that varies along the surface level.
  • the drift of the process chamber may for instance be caused by thermal expansion of elements of the process chamber.
  • the emitter unit is arranged for emitting a further electromagnetic radiation having a wavelength that is different from the wavelength of the beam of electromagnetic radiation for melting the selective layer-part of the powdered material of the bath of powdered material.
  • detection, by the detection unit is independent from the operating conditions of the solidifying device, the process parameters of the apparatus and/or the process conditions in the process chamber.
  • Drift of the scanner device relative to the defined coordinate system or the reference coordinate system may for instance be detected, by the detection unit, by determining the position of the further electromagnetic radiation before start of the production and subsequently, during manufacturing, detecting, by the detection unit, that a shift of the further electromagnetic radiation has occurred when the further electromagnetic radiation is emitted again.
  • the detection unit is arranged for detecting the further electromagnetic radiation at the surface level of the bath of powdered material or the support via the scanner device. This allows to arrive at an apparatus wherein the optical path of the detection unit and the solidifying device are at least partly identical, and preferably stationary relative to each other during manufacturing of the object.
  • the detection unit is arranged such that an optical path of the further electromagnetic radiation, between the bath of powdered material or the support and the detection unit, bypasses the scanner device for detecting the further electromagnetic radiation.
  • the emitter unit comprises a further solidifying device arranged for emitting the beam of further electromagnetic radiation, wherein the beam of further electromagnetic radiation is further arranged for melting a further selective layer-part of the powdered material of the bath of powdered material. This is beneficial for allowing correction of drift of the solidifying device and the further solidifying device relative to each other.
  • the apparatus according to the present disclosure further comprises a further scanner device arranged for moving the beam of further electromagnetic radiation along the surface level of the bath of powdered material. This is beneficial for allowing correction of drift of the scanner device relative to the further scanner device.
  • the detection unit is arranged for detecting a wavelength in a range comprising the wavelength of the further electromagnetic radiation and excluding the wavelength of the beam of electromagnetic radiation.
  • This is beneficial for realising a relative high signal to noise ratio for the detection unit.
  • any radiation of the beam of electromagnetic radiation and/or radiation originating from the solidification process is considered noise.
  • a relative high signal to noise ratio is beneficial for allowing the detection unit to receive a relative strong signal of the further electromagnetic radiation and allowing the apparatus to notify relatively accurately drift and either correct for the drift of stop manufacturing of the object.
  • the solidifying device comprises the emitter unit, preferably wherein the solidifying device comprises a laser source arranged for emitting the further electromagnetic radiation.
  • the emitter unit is integrated in the solidifying device.
  • the solidifying device may be integrated into the apparatus as a module without a further need to align parts of the apparatus for a possible alignment of the emitter unit with the solidifying device.
  • the emitter unit may be aligned with the beam of electromagnetic radiation for melting the selective layer-part independently from the internal alignment of parts of the apparatus, thereby allowing to realise a relative high accuracy of producing the object while avoiding a relative cumbersome alignment and/or wiring to two separate parts being the emitter unit and the solidifying device.
  • the solidifying device comprises a laser device arranged for emitting the beam of electromagnetic radiation for melting the selective layer-part of the powdered material of the bath of powdered material, wherein the emitter unit is integrated in the laser device.
  • the laser device may be integrated into the apparatus as a module without a further need to align parts of the apparatus for a possible alignment of the emitter unit with the beam of solidifying device.
  • the emitter unit may be aligned with the beam of electromagnetic radiation for melting the selective layer-part independently from the internal alignment of parts of the apparatus, thereby allowing to realise a relative high accuracy of producing the object while avoiding a relative cumbersome alignment and/or wiring to two separate parts being the emitter unit and the solidifying device.
  • the laser device comprises a further laser source arranged for emitting the further electromagnetic radiation.
  • the scanner device is arranged for moving the beam of the further electromagnetic radiation along the surface level or the support in a predetermined spatial pattern and wherein the detection unit is arranged for detecting the predetermined spatial pattern.
  • the scanner device is arranged for moving a beam of the further electromagnetic radiation along the surface level or the support in a predetermined spatial pattern and the detection unit is arranged such that the optical path of the further electromagnetic radiation, between the bath of powdered material or the support and the detection unit, bypasses the scanner device for detecting the further electromagnetic radiation.
  • This allows to arrive at an apparatus wherein the optical path of the emitter unit and the solidifying device are at least partly identical, and preferably stationary relative to each other during manufacturing of the object while the detection unit is not affected by drift of the scanner device.
  • the detection unit is arranged such that the optical path of the further electromagnetic radiation, between the bath of powdered material or the support and the detection unit, bypasses any scanner device of the apparatus for detecting the further electromagnetic radiation.
  • the emitter unit is arranged such that a further optical path of the further electromagnetic radiation, between the bath of powdered material or the support and the emitter unit, bypasses the scanner device for providing a predetermined spatial pattern of the further electromagnetic radiation on the surface level or the support and wherein the scanner device is arranged for moving a detection area of the detection unit along the surface level or the support for detecting, by the detection unit, the predetermined spatial pattern.
  • the emitter unit is arranged such that the optical path of the further electromagnetic radiation, between the bath of powdered material or the support and the emitter unit, bypasses the scanner device and the detection unit is arranged for detecting the further electromagnetic radiation at the surface level of the bath of powdered material or the support via the scanner device. This allows to arrive at an apparatus wherein the optical path of the detection unit and the solidifying device are at least partly identical, and preferably stationary relative to each other during manufacturing of the object while the emitter unit is not affected by drift of the scanner device.
  • the optical path of the further electromagnetic radiation, between the bath of powdered material or the support and the emitter unit, bypasses any scanner device comprises by the apparatus.
  • Drift of the scanner device relative to the coordinate system may for instance be detected, by the detection unit, by determining the position of the predetermined spatial pattern, an element or a plurality of elements thereof before start of the production and subsequently, during manufacturing, detecting, by the detection unit, that a shift of the predetermined spatial pattern or an element of the predetermined spatial pattern has occurred when the predetermined spatial pattern is emitted again.
  • the position dependent drift may for instance be determined by determining mutual positions of elements of the plurality of elements, i.e. a distance between elements, preferably neighbouring elements of the plurality of elements.
  • the position of the detection unit and/or the emitter unit is fixed relative to the process chamber. This is beneficial for allowing to realize a relative accurate determination of drift of the scanner device, thereby allowing a relative accurate calibration.
  • the apparatus further comprises: a determining unit, communicatively coupled to the scanner device and the detection unit, arranged for determining that an actual position of an element of the predetermined spatial pattern differs from an expected position of the element of the predetermined spatial pattern; a calibration unit, communicatively coupled to the determining unit, arranged for generating updated calibration data taking into account the difference, determined by the determining unit, between the actual position and the expected position, such that an updated actual position of the element of the predetermined spatial pattern corresponds to the expected position of the element of the predetermined spatial pattern; and a control unit, communicatively coupled to the scanner device and the calibration unit, arranged for controlling the scanner device according to the calibration data.
  • a determining unit communicatively coupled to the scanner device and the detection unit, arranged for determining that an actual position of an element of the predetermined spatial pattern differs from an expected position of the element of the predetermined spatial pattern
  • a calibration unit communicatively coupled to the determining unit, arranged for generating updated calibration data taking into account the difference,
  • a drift of the scanner device may be determined, by the determining unit, through a comparison of the actual position and the expected position of the element of the predetermined spatial pattern.
  • the determining unit determines that the actual position of the element differs from the expected position, calibration of the scanner device is required as regards the element of the predetermined spatial pattern.
  • the determining unit is arranged for determining that the difference between the actual position of the element of the predetermined spatial pattern and the expected position of the element of the predetermined spatial pattern exceeds a predetermined distance.
  • the calibration unit is arranged for generating the updated calibration data when the determining unit determines that the difference exceeds the predetermined distance and maintain current calibration data when the determining unit determines that the difference is less than the predetermined distance. This is beneficial for allowing to realize a relative high accuracy of producing the object while maintaining a relative short manufacturing time.
  • the apparatus according to the first aspect of the present disclosure is further provided with a recoating device comprising: - a supply unit for supplying a layer of powdered material to the bath of powdered material; and
  • a levelling unit which is arranged to be displaced along the surface level of the bath of powdered material for levelling the surface level of the bath of powdered material.
  • the emitter unit is arranged for emitting the further electromagnetic radiation on the surface level of the bath of powdered material or the support during or after the levelling, by the levelling unit, of the surface level, during production of the object and/or;
  • the detection unit is arranged for detecting the further electromagnetic radiation during or after the levelling, by the levelling unit, of the surface level, during production of the object and/or;
  • the determining unit is arranged for determining that the actual position of the element of the predetermined spatial pattern differs from the expected position of the element of the predetermined spatial pattern during, before or after the levelling, by the levelling unit, of the surface level, during production of the object.
  • the detection unit comprises a camera for detecting a position of the further electromagnetic radiation at the surface level of the bath of powdered material or the support.
  • a camera is beneficial for allowing to detect the position of the further electromagnetic radiation and/or an element of the predetermined spatial pattern in a relative accurate manner.
  • a camera allows to register a plurality of elements of the predetermined spatial pattern. This is beneficial for realizing a relative fast and accurate calibration of the apparatus.
  • the apparatus further comprises: a yet further solidifying device arranged for emitting a yet further beam of electromagnetic radiation for melting a yet further selective layer-part of the powdered material of the bath of powdered material; a yet further scanner device arranged for moving the yet further beam of electromagnetic radiation along the surface level of the bath of powdered material; wherein the detection unit is further arranged for detecting a position of the yet further electromagnetic radiation at the surface level of the bath of powdered material or the support via the yet further scanner device or arranged such that an optical path of the yet further beam of electromagnetic radiation, between the bath of powdered material or the support and the detection unit, bypasses the scanner device for detecting the position of the yet further beam of electromagnetic radiation at the surface level of the bath of powdered material or the
  • the present disclosure relates to a method of calibrating an apparatus for producing an object by means of additive manufacturing according to the first aspect of the present disclosure, the method comprising the steps of: emitting, by the emitter unit, the further electromagnetic radiation on the surface level of the bath of powdered material or the support; detecting, by the detection unit, a position of the emitted further electromagnetic radiation on the surface level of the bath of powdered material or the support.
  • Embodiments of the apparatus according to the first aspect correspond to or are similar to embodiments of the method according to the second aspect of the present disclosure.
  • Effects of the apparatus according to the first aspect correspond to or are similar to effects of the method according to the second aspect of the present disclosure.
  • the position of the further electromagnetic radiation at the surface level of the bath of powdered material or the support is detected by the camera of the detection unit.
  • the beam of the further electromagnetic radiation is moved, by the scanner device, along the surface level or the support in a predetermined spatial pattern and wherein, during the step of detecting, the detection unit detects the predetermined spatial pattern.
  • the emitter unit provides the predetermined spatial pattern of the further electromagnetic radiation on the surface level or the support and wherein, during the step of detecting, the detection area of the detection unit is moved, by the scanner device, along the surface level or the support for detecting the predetermined spatial pattern.
  • the method further comprises the steps of: determining, by the determining unit, that the actual position of the element of the predetermined spatial pattern differs from the expected position of the element of the predetermined spatial pattern; generating, by the calibration unit, updated calibration data taking into account the difference, determined by the determining unit, between the actual position and the expected position, such that the updated actual position of the element of the predetermined spatial pattern corresponds to the expected position of the element of the predetermined spatial pattern; and controlling, by the control unit, the scanner device according to the updated calibration data.
  • the method further comprises the steps of: supplying, by the supply unit, the layer of powdered material to the bath of powdered material; and levelling, by the levelling unit, the surface level of the bath of powdered material.
  • the method further comprises the steps of: emitting, by the emitter unit, the further electromagnetic radiation on the surface level of the bath of powdered material or the support during or after the step of levelling, by the levelling unit, of the surface level, during production of the object and/or; detecting, by the detection unit, the further electromagnetic radiation during or after the levelling, by the levelling unit, of the surface level, during production of the object and/or; determining, by the determining unit, that the actual position of the element of the predetermined spatial pattern differs from the expected position of the element of the predetermined spatial pattern during or after the levelling, by the levelling unit, of the surface level, during production of the object.
  • the method further comprises the step of: generating, by the calibration unit, updated calibration data taking into account the difference, determined during the step of determining, between the actual position and the expected position during or after the levelling, by the levelling unit, of the surface level, during production of the object.
  • the method further comprises the step of: controlling, by the control unit, the scanner device according to the updated calibration data during or after the levelling, by the levelling unit, of the surface level, during production of the object.
  • the method further comprises the steps of: receiving, by the process chamber, a bath of powdered material to produce the object; positioning, by the support, the object in relation to a surface level of the bath of powdered material; melting, by the solidifying device arranged for emitting a beam of electromagnetic radiation, a selective layer-part of the powdered material of the bath of powdered material; moving, by the scanner device, the beam of electromagnetic radiation along the surface level of the bath of powdered material.
  • the apparatus is arranged for performing the steps of determining and/or generating before a predetermined step of levelling.
  • an interval between the predetermined step of levelling and a subsequent predetermined step of levelling is a predetermined interval.
  • the predetermined interval is larger than one step of levelling. This is beneficial for allowing to realize a relative high accuracy of producing the object while maintaining a relative short manufacturing time by avoiding determining the difference and/or generating calibration data before every step of levelling
  • the predetermined interval is a predetermined time period or a predetermined number of levelling steps. This is beneficial for allowing to realize a relative high accuracy of producing the object while maintaining a relative short manufacturing time by avoiding determining the difference and/or generating calibration data before every step of levelling.
  • Fig. 1 a side view of an apparatus according to the first aspect of the present disclosure is shown;
  • Fig. 2 a side view of another apparatus according to the first aspect of the present disclosure is shown;
  • Fig. 3 a side view of yet another apparatus according to the first aspect of the present disclosure is shown;
  • Fig. 4 a side view of a further apparatus according to the first aspect of the present disclosure is shown;
  • Fig. 5 a side view of yet a further apparatus according to the first aspect of the present disclosure is shown;
  • Fig. 6 a method of operating the apparatus according to Fig. 1 , Fig. 2, Fig. 4 or Fig. 5 is shown;
  • Fig. 7 a method of operating the apparatus according to Fig. 3 is shown.
  • Fig. 1 is shown a side view of an apparatus 1 according to the first aspect of the present disclosure.
  • the apparatus 1 comprises a process chamber 5 for receiving a bath of powdered material 7 to produce an object 3, a support 9 for positioning the object 3 in relation to a surface level L of the bath of powdered material 7, a semitransparent mirror 11 , and a solidifying device 13 arranged for emitting a beam of electromagnetic radiation 15.
  • the beam of electromagnetic radiation 15 is suitable for melting a selective layer-part of the powdered material in the bath of powdered material 7.
  • the apparatus 1 also comprises a scanner device 17 arranged for moving the beam of electromagnetic radiation 15 along the surface level L of the bath of powdered material 7.
  • the apparatus 1 further comprises an emitter unit 19, a detection unit 23, comprising a camera 39.
  • the emitter unit 19 is arranged for emitting a beam of further electromagnetic radiation 21 on the surface level L of the bath of powdered material 7 or the support 9.
  • a wavelength of the beam of electromagnetic radiation 15 and a wavelength of the further beam of electromagnetic radiation 21 are different.
  • the scanner device 17 is arranged for moving the beam of the further electromagnetic radiation 21 along the surface level L or the support 9 in a predetermined spatial pattern and the detection unit 23 is arranged such that the optical path of the further electromagnetic radiation 21 , between the bath of powdered material 7 or the support 9 and the detection unit 23, bypasses the scanner device 17 for detecting the further electromagnetic radiation 21.
  • the detection unit 23 is arranged such that it may detect the predetermined spatial pattern or at least an element or further element of the predetermined spatial pattern.
  • the apparatus 1 as shown in Fig. 1 further comprises a determining unit 27, a calibration unit 29, and a control unit 31.
  • the determining unit 27 is communicatively coupled to the scanner device 17 and the detection unit 23 and is arranged for determining that an actual position of an element of the predetermined spatial pattern differs from an expected position of the element of the predetermined spatial pattern.
  • the calibration unit 29 is coupled to the determining unit 27 and arranged for generating updated calibration data taking into account the difference, determined by the determining unit 27, between the actual position and the expected position, such that an updated actual position of the element of the predetermined spatial pattern corresponds to the expected position of the element of the predetermined spatial pattern.
  • the control unit 31 is communicatively coupled to the scanner device 17 and the calibration unit 29 and arranged for controlling the scanner device 17 according to the updated calibration data.
  • the apparatus 1 also comprises a recoating device 33, comprising a supply unit 35 for supplying a layer of powdered material 7 to the bath of powdered material 7, and a levelling unit 37 which is arranged to be displaced along the surface level L of the bath of powdered material 7 for levelling the surface level L of the bath of powdered material 7.
  • a recoating device 33 comprising a supply unit 35 for supplying a layer of powdered material 7 to the bath of powdered material 7, and a levelling unit 37 which is arranged to be displaced along the surface level L of the bath of powdered material 7 for levelling the surface level L of the bath of powdered material 7.
  • FIG. 2 A side view of an apparatus 401 according to the first aspect of the present disclosure is shown in Fig. 2. Elements of apparatus 401 that are identical or similar to elements of apparatus 1 are provided with the same reference numerals.
  • the solidifying device 13 comprises the emitter unit 19 and a laser source 25 such that the laser source 25 is arranged for emitting the further electromagnetic radiation 21 and the electromagnetic radiation 15.
  • the solidifying device 13 comprises a laser device arranged for emitting the beam of electromagnetic radiation 15 for melting the selective layer-part of the powdered material of the bath of powdered material 7, wherein the emitter unit 19 is integrated in the laser device.
  • the laser device may further comprise a further laser source 25 arranged for emitting the further electromagnetic radiation 21.
  • Fig. 3 is shown a side view of an apparatus 101 according to the first aspect of the present disclosure. Elements of apparatus 101 that are identical or similar to elements of apparatus 1 are provided with the same reference numerals.
  • the emitter unit 19 is arranged such that the optical path of the further electromagnetic radiation 21 , between the bath of powdered material 7 or the support 9 and the emitter unit 19, bypasses the scanner device 17.
  • the detection unit 23 is arranged for detecting the further electromagnetic radiation 21 at the surface level L of the bath of powdered material 7 or the support 9 via the scanner device 17.
  • the scanner device 17 is arranged for moving a detection area of the detection unit 23 along the surface level L or the support 9 for detecting, by the detection unit 23, the predetermined spatial pattern or at least an element or further element of the predetermined spatial pattern.
  • FIG. 4 A side view of an apparatus 501 according to the first aspect of the present disclosure is shown in Fig. 4. Elements of apparatus 501 that are identical or similar to elements of apparatus 1 and/or 401 are provided with the same reference numerals.
  • the emitter unit 19 comprises a further solidifying device 41 arranged for emitting the beam of further electromagnetic radiation 21 , wherein the beam of further electromagnetic radiation 21 is further arranged for melting a further selective layer-part of the powdered material of the bath of powdered material 7.
  • the apparatus 501 further comprises a further scanner device 43 arranged for moving the beam of further electromagnetic radiation 21 along the surface level L of the bath of powdered material 7.
  • Fig. 5 shows a side view of an apparatus 601 according to the present disclosure. Elements of apparatus 601 that are identical or similar to elements of apparatus 1 , 401 and/or 501 are provided with the same reference numerals.
  • the apparatus 601 comprises a yet further solidifying device 45 arranged for emitting a yet further beam of electromagnetic radiation 47 for melting a yet further selective layerpart of the powdered material of the bath of powdered material 7.
  • the apparatus 601 further comprises a yet further scanner device 49 arranged for moving the yet further beam of electromagnetic radiation 47 along the surface level L of the bath of powdered material 7.
  • the detection unit 23 is further arranged such that an optical path of the yet further beam of electromagnetic radiation 47, between the bath of powdered material 7 or the support 9 and the detection unit 23, bypasses the yet further scanner device 49 for detecting the position of the yet further beam of electromagnetic radiation 47 at the surface level L of the bath of powdered material 7 or the support 9.
  • the detection unit 23 instead of arranging the detection unit 23 such that an optical path of the yet further beam of electromagnetic radiation 47, between the bath of powdered material 7 or the support 9 and the detection unit 23, bypasses the yet further scanner device 49 for detecting the position of the yet further beam of electromagnetic radiation 47 at the surface level L of the bath of powdered material 7 or the support 9, the detection unit 23 of the apparatus 601 may also be arranged for detecting a position of the yet further electromagnetic radiation 47 at the surface level L of the bath of powdered material 7 or the support 9 via the yet further scanner device 49.
  • the apparatus 1 may be used during a method 201 for manufacturing the object 3.
  • the beam of the further electromagnetic radiation 21 is moved, by the scanner device 17, along the surface level L or the support 9 in the predetermined spatial pattern and during the step of detecting 205 of the method 201 , and during a step of detecting 205 of the method 201 , the detection unit 23 detects the predetermined spatial pattern.
  • a pattern of the emitted further electromagnetic radiation 21 on the surface level L of the bath of powdered material 7 or the support 9 the detected pattern may differ relative to the predetermined spatial pattern that is expected to be detected by the detection unit 23 and this could be an indication that the scanner device 17 needs to be recalibrated.
  • the method 201 as shown in Fig. 6 further comprises the steps of determining 207 that the actual position of the element of the predetermined spatial pattern differs from the expected position of the element of the predetermined spatial pattern, generating 209 updated calibration data taking into account the difference between the actual position and the expected position, such that the updated actual position of the element of the predetermined spatial pattern corresponds to the expected position of the element of the predetermined spatial pattern, controlling 211 the scanner device 17 according to the updated calibration data, supplying 213 the layer of powdered material 7 to the bath of powdered material 7, and levelling 215 the surface level L of the bath of powdered material 7.
  • the method 201 further comprises the steps of emitting 217 the further electromagnetic radiation 21 on the surface level L of the bath of powdered material 7 or the support 9 after the step of levelling 215 of the surface level L during production of the object 3, detecting 219 the further electromagnetic radiation 21 after the step of levelling 215 of the surface level L during production of the object 3, and determining 221 that the actual position of the element of the predetermined spatial pattern differs from the expected position of the element of the predetermined spatial pattern after the step of levelling 215 of the surface level L during production of the object 3.
  • the method 201 as shown in Fig. 6 also comprises the steps of generating 223 updated calibration data taking into account the difference between the actual position and the expected position after the step of levelling 215 of the surface level L during production of the object 3, and controlling 225 the scanner device 17 according to the updated calibration data after the step of levelling 215 of the surface level L during production of the object 3.
  • the apparatus 101 may be used during a method 301 for manufacturing the object 3.
  • the emitter unit 19 provides the predetermined spatial pattern of the further electromagnetic radiation 21 on the surface level L or the support 9 and during the step of detecting 305 of the method 301 , the detection area of the detection unit 23 is moved, by the scanner device 17, along the surface level L or the support 9 for detecting the predetermined spatial pattern.
  • the detector unit 23 may detect via the scanner device 17 a pattern of the further electromagnetic radiation 21 that is different relative to the predetermined spatial pattern of the emitted further electromagnetic radiation 21 , provided by the emitter unit 19, on the surface level L of the bath of powdered material 7 or the support 9 and this could be an indication that the scanner device 17 needs to be recalibrated.
  • Steps following after the step of detecting 205 of method 201 are identical or similar to steps following after the step of detecting 305 of method 301 and are provided with the same reference numerals increased by a hundred.

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Abstract

An apparatus for producing an object by means of additive manufacturing, the apparatus comprising: - a process chamber for receiving a bath of powdered material to produce the object; - a support for positioning the object in relation to a surface level of the bath of powdered material; - a solidifying device arranged for emitting a beam of electromagnetic radiation for melting a selective layer-part of the powdered material of the bath of powdered material; - a scanner device arranged for moving the beam of electromagnetic radiation along the surface level of the bath of powdered material; - an emitter unit arranged for emitting further electromagnetic radiation on the surface level of the bath of powdered material or the support; - a detection unit arranged for detecting a position of the further electromagnetic radiation at the surface level of the bath of powdered material or the support via the scanner device or arranged such that an optical path of the further electromagnetic radiation, between the bath of powdered material or the support and the detection unit, bypasses the scanner device for detecting the position of the further electromagnetic radiation. A method of calibrating an apparatus for producing an object by means of additive manufacturing.

Description

AN APPARATUS FOR PRODUCING AN OBJECT BY POWDER BED ADDITIVE MANUFACTURING AND A METHOD OF CALIBRATING THE APPARATUS
Description:
According to the first aspect, the present disclosure relates to an apparatus for producing an object by means of additive manufacturing, the apparatus comprising: a process chamber for receiving a bath of powdered material to produce the object; a support for positioning the object in relation to a surface level of the bath of powdered material; a solidifying device arranged for emitting a beam of electromagnetic radiation for melting a selective layer-part of the powdered material of the bath of powdered material; a scanner device arranged for moving the beam of electromagnetic radiation along the surface level of the bath of powdered material.
According to the second aspect, the present disclosure relates to a method of calibrating an apparatus according to the first aspect of the present disclosure.
3D printing or additive manufacturing refers to any of various processes for manufacturing a three-dimensional object in which material is joined or solidified under computer control to create a three-dimensional object, with material being added together, typically layer by layer.
One of the challenges in the manufacturing of three dimensional objects, in particular in additive manufacturing of metal objects, is how to accurately solidify selective parts of the layer.
It is an object to provide an apparatus and a method that allows to realize a relative high accuracy of producing the object.
This object is achieved by the apparatus according to the present disclosure, wherein the apparatus comprises: an emitter unit arranged for emitting further electromagnetic radiation, preferably a beam of further electromagnetic radiation, on the surface level of the bath of powdered material or the support; a detection unit arranged for detecting a position of the further electromagnetic radiation, preferably the beam of further electromagnetic radiation, at the surface level of the bath of powdered material or the support via the scanner device or arranged such that an optical path of the further electromagnetic radiation, preferably the beam of further electromagnetic radiation, between the bath of powdered material or the support and the detection unit, bypasses the scanner device for detecting the position of the further electromagnetic radiation, preferably the beam of further electromagnetic radiation, at the surface level of the bath of powdered material or the support.
The present disclosure relies at least partly on the insight that for the manufacturing of three-dimensional objects, in particular in additive manufacturing of metal objects, the manufacturing of the object may require the apparatus for manufacturing the object to run for a relative long time period. During this period it is beneficial if the beam of electromagnetic radiation for melting a selective layer-part of the powdered material of the bath of powdered material is moved such that it operates within a defined accuracy of a defined coordinate system. If the apparatus or a component thereof such as the scanner device, the process chamber and/or the solidifying device drift during the period of manufacturing relative to the defined coordinate system the geometrical accuracy of the object may be negatively affected.
It is noted that within the context of the present disclosure, drift may relate a uniform drift of the beam of electromagnetic radiation along the surface level of the bath of powdered material relative to the defined coordinate system or a reference coordinate system relating to a corresponding position of the beam of electromagnetic radiation at a previous instance, such as before the start of the manufacturing of the object or during manufacturing of the object. This uniform drift may be due to a drift of the scanner device and/or the solidifying device that is independent on the position of the beam of electromagnetic radiation at the surface level. In other words, the uniform drift causes a shift that is equal at the whole surface level. Alternative, or in addition to the drift related to the uniform drift, the drift within the context of the present disclosure may also relate to a position dependent drift that is dependent on the position of the beam of electromagnetic radiation along the surface level of the bath of powdered material relative to the defined coordinate system or the reference coordinate system relating to the corresponding position of the beam of electromagnetic radiation at the previous instance, such as before the start of the manufacturing of the object or during manufacturing of the object. This position dependent drift may due to a drift of the scanner device that is dependent on the position of the beam of electromagnetic radiation at the surface level. In other words, the position dependent drift causes a shift that varies along the surface level.
Within the context of the present disclosure, the drift of the process chamber may for instance be caused by thermal expansion of elements of the process chamber.
In a method known from US 5,832,415 calibration of the apparatus is done only before starting manufacturing of the object or after manufacturing of the object is completed. By providing the apparatus with the emitter unit and the detection unit, a drift of the scanning device may be detected during manufacturing of the object, thereby allowing notification of drift and either correcting for the drift or stopping manufacturing of the object.
Preferably, the emitter unit is arranged for emitting a further electromagnetic radiation having a wavelength that is different from the wavelength of the beam of electromagnetic radiation for melting the selective layer-part of the powdered material of the bath of powdered material. This is beneficial for realizing an apparatus wherein detection, by the detection unit, is independent from the operating conditions of the solidifying device, the process parameters of the apparatus and/or the process conditions in the process chamber.
Drift of the scanner device relative to the defined coordinate system or the reference coordinate system may for instance be detected, by the detection unit, by determining the position of the further electromagnetic radiation before start of the production and subsequently, during manufacturing, detecting, by the detection unit, that a shift of the further electromagnetic radiation has occurred when the further electromagnetic radiation is emitted again.
In a first embodiment of the apparatus according to the present disclosure, the detection unit is arranged for detecting the further electromagnetic radiation at the surface level of the bath of powdered material or the support via the scanner device. This allows to arrive at an apparatus wherein the optical path of the detection unit and the solidifying device are at least partly identical, and preferably stationary relative to each other during manufacturing of the object.
In a further embodiment of the apparatus according to the present disclosure, the detection unit is arranged such that an optical path of the further electromagnetic radiation, between the bath of powdered material or the support and the detection unit, bypasses the scanner device for detecting the further electromagnetic radiation.
In an embodiment of the apparatus according to the present disclosure, the emitter unit comprises a further solidifying device arranged for emitting the beam of further electromagnetic radiation, wherein the beam of further electromagnetic radiation is further arranged for melting a further selective layer-part of the powdered material of the bath of powdered material. This is beneficial for allowing correction of drift of the solidifying device and the further solidifying device relative to each other.
In this regard, it is beneficial if the apparatus according to the present disclosure further comprises a further scanner device arranged for moving the beam of further electromagnetic radiation along the surface level of the bath of powdered material. This is beneficial for allowing correction of drift of the scanner device relative to the further scanner device.
Preferably, the detection unit is arranged for detecting a wavelength in a range comprising the wavelength of the further electromagnetic radiation and excluding the wavelength of the beam of electromagnetic radiation. This is beneficial for realising a relative high signal to noise ratio for the detection unit. In this regard it is noticed that any radiation of the beam of electromagnetic radiation and/or radiation originating from the solidification process is considered noise. A relative high signal to noise ratio is beneficial for allowing the detection unit to receive a relative strong signal of the further electromagnetic radiation and allowing the apparatus to notify relatively accurately drift and either correct for the drift of stop manufacturing of the object.
It is advantageous, if the solidifying device comprises the emitter unit, preferably wherein the solidifying device comprises a laser source arranged for emitting the further electromagnetic radiation.
In a very practical embodiment of the apparatus, the emitter unit is integrated in the solidifying device. By integrating the emitter unit within the solidifying device the solidifying device may be integrated into the apparatus as a module without a further need to align parts of the apparatus for a possible alignment of the emitter unit with the solidifying device. In other words, the emitter unit may be aligned with the beam of electromagnetic radiation for melting the selective layer-part independently from the internal alignment of parts of the apparatus, thereby allowing to realise a relative high accuracy of producing the object while avoiding a relative cumbersome alignment and/or wiring to two separate parts being the emitter unit and the solidifying device.
Preferably, the solidifying device comprises a laser device arranged for emitting the beam of electromagnetic radiation for melting the selective layer-part of the powdered material of the bath of powdered material, wherein the emitter unit is integrated in the laser device. By integrating the emitter unit in the laser device, the laser device may be integrated into the apparatus as a module without a further need to align parts of the apparatus for a possible alignment of the emitter unit with the beam of solidifying device. In other words, the emitter unit may be aligned with the beam of electromagnetic radiation for melting the selective layer-part independently from the internal alignment of parts of the apparatus, thereby allowing to realise a relative high accuracy of producing the object while avoiding a relative cumbersome alignment and/or wiring to two separate parts being the emitter unit and the solidifying device. Preferably, the laser device comprises a further laser source arranged for emitting the further electromagnetic radiation.
In an embodiment, the scanner device is arranged for moving the beam of the further electromagnetic radiation along the surface level or the support in a predetermined spatial pattern and wherein the detection unit is arranged for detecting the predetermined spatial pattern. This allows to arrive at an apparatus wherein the optical path of the beam of the further electromagnetic radiation and the beam of electromagnetic radiation are at least partly identical, and preferably stationary relative to each other during manufacturing of the object.
In this regard, it is beneficial if the scanner device is arranged for moving a beam of the further electromagnetic radiation along the surface level or the support in a predetermined spatial pattern and the detection unit is arranged such that the optical path of the further electromagnetic radiation, between the bath of powdered material or the support and the detection unit, bypasses the scanner device for detecting the further electromagnetic radiation. This allows to arrive at an apparatus wherein the optical path of the emitter unit and the solidifying device are at least partly identical, and preferably stationary relative to each other during manufacturing of the object while the detection unit is not affected by drift of the scanner device.
Preferably, the detection unit is arranged such that the optical path of the further electromagnetic radiation, between the bath of powdered material or the support and the detection unit, bypasses any scanner device of the apparatus for detecting the further electromagnetic radiation.
In another embodiment, the emitter unit is arranged such that a further optical path of the further electromagnetic radiation, between the bath of powdered material or the support and the emitter unit, bypasses the scanner device for providing a predetermined spatial pattern of the further electromagnetic radiation on the surface level or the support and wherein the scanner device is arranged for moving a detection area of the detection unit along the surface level or the support for detecting, by the detection unit, the predetermined spatial pattern. In this regard, it is beneficial if the emitter unit is arranged such that the optical path of the further electromagnetic radiation, between the bath of powdered material or the support and the emitter unit, bypasses the scanner device and the detection unit is arranged for detecting the further electromagnetic radiation at the surface level of the bath of powdered material or the support via the scanner device. This allows to arrive at an apparatus wherein the optical path of the detection unit and the solidifying device are at least partly identical, and preferably stationary relative to each other during manufacturing of the object while the emitter unit is not affected by drift of the scanner device.
Preferably, the optical path of the further electromagnetic radiation, between the bath of powdered material or the support and the emitter unit, bypasses any scanner device comprises by the apparatus.
Drift of the scanner device relative to the coordinate system may for instance be detected, by the detection unit, by determining the position of the predetermined spatial pattern, an element or a plurality of elements thereof before start of the production and subsequently, during manufacturing, detecting, by the detection unit, that a shift of the predetermined spatial pattern or an element of the predetermined spatial pattern has occurred when the predetermined spatial pattern is emitted again.
The position dependent drift may for instance be determined by determining mutual positions of elements of the plurality of elements, i.e. a distance between elements, preferably neighbouring elements of the plurality of elements.
Preferably, the position of the detection unit and/or the emitter unit is fixed relative to the process chamber. This is beneficial for allowing to realize a relative accurate determination of drift of the scanner device, thereby allowing a relative accurate calibration.
Preferably, the apparatus further comprises: a determining unit, communicatively coupled to the scanner device and the detection unit, arranged for determining that an actual position of an element of the predetermined spatial pattern differs from an expected position of the element of the predetermined spatial pattern; a calibration unit, communicatively coupled to the determining unit, arranged for generating updated calibration data taking into account the difference, determined by the determining unit, between the actual position and the expected position, such that an updated actual position of the element of the predetermined spatial pattern corresponds to the expected position of the element of the predetermined spatial pattern; and a control unit, communicatively coupled to the scanner device and the calibration unit, arranged for controlling the scanner device according to the calibration data.
By providing the determining unit a drift of the scanner device may be determined, by the determining unit, through a comparison of the actual position and the expected position of the element of the predetermined spatial pattern. In case the determining unit determines that the actual position of the element differs from the expected position, calibration of the scanner device is required as regards the element of the predetermined spatial pattern.
Preferably, the determining unit is arranged for determining that the difference between the actual position of the element of the predetermined spatial pattern and the expected position of the element of the predetermined spatial pattern exceeds a predetermined distance.
In this regard, it is advantageous, if the calibration unit is arranged for generating the updated calibration data when the determining unit determines that the difference exceeds the predetermined distance and maintain current calibration data when the determining unit determines that the difference is less than the predetermined distance. This is beneficial for allowing to realize a relative high accuracy of producing the object while maintaining a relative short manufacturing time.
Preferably, the apparatus according to the first aspect of the present disclosure is further provided with a recoating device comprising: - a supply unit for supplying a layer of powdered material to the bath of powdered material; and
- a levelling unit which is arranged to be displaced along the surface level of the bath of powdered material for levelling the surface level of the bath of powdered material.
In this regard, it is beneficial if the emitter unit is arranged for emitting the further electromagnetic radiation on the surface level of the bath of powdered material or the support during or after the levelling, by the levelling unit, of the surface level, during production of the object and/or; the detection unit is arranged for detecting the further electromagnetic radiation during or after the levelling, by the levelling unit, of the surface level, during production of the object and/or; the determining unit is arranged for determining that the actual position of the element of the predetermined spatial pattern differs from the expected position of the element of the predetermined spatial pattern during, before or after the levelling, by the levelling unit, of the surface level, during production of the object.
Preferably, the detection unit comprises a camera for detecting a position of the further electromagnetic radiation at the surface level of the bath of powdered material or the support. A camera is beneficial for allowing to detect the position of the further electromagnetic radiation and/or an element of the predetermined spatial pattern in a relative accurate manner.
In addition, a camera allows to register a plurality of elements of the predetermined spatial pattern. This is beneficial for realizing a relative fast and accurate calibration of the apparatus.
It is beneficial if at least one of the detection unit and the emitter unit is maintained in a predetermined position relative to the support and/or the surface level of the bath of powdered material. This is beneficial for realizing a relative accurate measure of the drift of the scanner device. Preferably, the apparatus further comprises: a yet further solidifying device arranged for emitting a yet further beam of electromagnetic radiation for melting a yet further selective layer-part of the powdered material of the bath of powdered material; a yet further scanner device arranged for moving the yet further beam of electromagnetic radiation along the surface level of the bath of powdered material; wherein the detection unit is further arranged for detecting a position of the yet further electromagnetic radiation at the surface level of the bath of powdered material or the support via the yet further scanner device or arranged such that an optical path of the yet further beam of electromagnetic radiation, between the bath of powdered material or the support and the detection unit, bypasses the scanner device for detecting the position of the yet further beam of electromagnetic radiation at the surface level of the bath of powdered material or the support.
According to the second aspect, the present disclosure relates to a method of calibrating an apparatus for producing an object by means of additive manufacturing according to the first aspect of the present disclosure, the method comprising the steps of: emitting, by the emitter unit, the further electromagnetic radiation on the surface level of the bath of powdered material or the support; detecting, by the detection unit, a position of the emitted further electromagnetic radiation on the surface level of the bath of powdered material or the support.
Embodiments of the apparatus according to the first aspect correspond to or are similar to embodiments of the method according to the second aspect of the present disclosure.
Effects of the apparatus according to the first aspect correspond to or are similar to effects of the method according to the second aspect of the present disclosure. Preferably, during the step of detecting, the position of the further electromagnetic radiation at the surface level of the bath of powdered material or the support is detected by the camera of the detection unit.
Preferably, during the step of emitting, the beam of the further electromagnetic radiation, is moved, by the scanner device, along the surface level or the support in a predetermined spatial pattern and wherein, during the step of detecting, the detection unit detects the predetermined spatial pattern. This allows to arrive at a method wherein the optical path of the beam of the further electromagnetic radiation and the beam of electromagnetic radiation are at least partly identical, and preferably stationary relative to each other during manufacturing of the object.
It is beneficial if, during the step of emitting, the emitter unit provides the predetermined spatial pattern of the further electromagnetic radiation on the surface level or the support and wherein, during the step of detecting, the detection area of the detection unit is moved, by the scanner device, along the surface level or the support for detecting the predetermined spatial pattern. This allows to arrive at a method wherein the optical path of the detection unit and the solidifying device are at least partly identical, and preferably stationary relative to each other during manufacturing of the object while the emitter unit is not affected by drift of the scanner device.
Preferably, the method further comprises the steps of: determining, by the determining unit, that the actual position of the element of the predetermined spatial pattern differs from the expected position of the element of the predetermined spatial pattern; generating, by the calibration unit, updated calibration data taking into account the difference, determined by the determining unit, between the actual position and the expected position, such that the updated actual position of the element of the predetermined spatial pattern corresponds to the expected position of the element of the predetermined spatial pattern; and controlling, by the control unit, the scanner device according to the updated calibration data. Preferably, the method further comprises the steps of: supplying, by the supply unit, the layer of powdered material to the bath of powdered material; and levelling, by the levelling unit, the surface level of the bath of powdered material.
In this regard, it is advantageous if the method further comprises the steps of: emitting, by the emitter unit, the further electromagnetic radiation on the surface level of the bath of powdered material or the support during or after the step of levelling, by the levelling unit, of the surface level, during production of the object and/or; detecting, by the detection unit, the further electromagnetic radiation during or after the levelling, by the levelling unit, of the surface level, during production of the object and/or; determining, by the determining unit, that the actual position of the element of the predetermined spatial pattern differs from the expected position of the element of the predetermined spatial pattern during or after the levelling, by the levelling unit, of the surface level, during production of the object.
Preferably, the method further comprises the step of: generating, by the calibration unit, updated calibration data taking into account the difference, determined during the step of determining, between the actual position and the expected position during or after the levelling, by the levelling unit, of the surface level, during production of the object.
Preferably, the method further comprises the step of: controlling, by the control unit, the scanner device according to the updated calibration data during or after the levelling, by the levelling unit, of the surface level, during production of the object.
In an embodiment of the method according to the second aspect of the present disclosure, the method further comprises the steps of: receiving, by the process chamber, a bath of powdered material to produce the object; positioning, by the support, the object in relation to a surface level of the bath of powdered material; melting, by the solidifying device arranged for emitting a beam of electromagnetic radiation, a selective layer-part of the powdered material of the bath of powdered material; moving, by the scanner device, the beam of electromagnetic radiation along the surface level of the bath of powdered material.
In an embodiment of the method according to the second disclosure, the apparatus is arranged for performing the steps of determining and/or generating before a predetermined step of levelling.
In this regard, it is beneficial if an interval between the predetermined step of levelling and a subsequent predetermined step of levelling is a predetermined interval.
Preferably the predetermined interval is larger than one step of levelling. This is beneficial for allowing to realize a relative high accuracy of producing the object while maintaining a relative short manufacturing time by avoiding determining the difference and/or generating calibration data before every step of levelling
In this regard, it is advantageous if the predetermined interval is a predetermined time period or a predetermined number of levelling steps. This is beneficial for allowing to realize a relative high accuracy of producing the object while maintaining a relative short manufacturing time by avoiding determining the difference and/or generating calibration data before every step of levelling.
The present disclosure will now be explained by means of a description of embodiments of an apparatus according to the present disclosure and a method according to the present disclosure, in which reference is made to the following schematic figures, in which: Fig. 1 : a side view of an apparatus according to the first aspect of the present disclosure is shown;
Fig. 2: a side view of another apparatus according to the first aspect of the present disclosure is shown;
Fig. 3: a side view of yet another apparatus according to the first aspect of the present disclosure is shown;
Fig. 4: a side view of a further apparatus according to the first aspect of the present disclosure is shown;
Fig. 5: a side view of yet a further apparatus according to the first aspect of the present disclosure is shown;
Fig. 6: a method of operating the apparatus according to Fig. 1 , Fig. 2, Fig. 4 or Fig. 5 is shown;
Fig. 7: a method of operating the apparatus according to Fig. 3 is shown.
In Fig. 1 is shown a side view of an apparatus 1 according to the first aspect of the present disclosure. The apparatus 1 comprises a process chamber 5 for receiving a bath of powdered material 7 to produce an object 3, a support 9 for positioning the object 3 in relation to a surface level L of the bath of powdered material 7, a semitransparent mirror 11 , and a solidifying device 13 arranged for emitting a beam of electromagnetic radiation 15. The beam of electromagnetic radiation 15 is suitable for melting a selective layer-part of the powdered material in the bath of powdered material 7. The apparatus 1 also comprises a scanner device 17 arranged for moving the beam of electromagnetic radiation 15 along the surface level L of the bath of powdered material 7.
The apparatus 1 further comprises an emitter unit 19, a detection unit 23, comprising a camera 39. The emitter unit 19 is arranged for emitting a beam of further electromagnetic radiation 21 on the surface level L of the bath of powdered material 7 or the support 9. Preferably a wavelength of the beam of electromagnetic radiation 15 and a wavelength of the further beam of electromagnetic radiation 21 are different.
In Fig. 1 , the scanner device 17 is arranged for moving the beam of the further electromagnetic radiation 21 along the surface level L or the support 9 in a predetermined spatial pattern and the detection unit 23 is arranged such that the optical path of the further electromagnetic radiation 21 , between the bath of powdered material 7 or the support 9 and the detection unit 23, bypasses the scanner device 17 for detecting the further electromagnetic radiation 21. The detection unit 23 is arranged such that it may detect the predetermined spatial pattern or at least an element or further element of the predetermined spatial pattern.
The apparatus 1 as shown in Fig. 1 further comprises a determining unit 27, a calibration unit 29, and a control unit 31. The determining unit 27 is communicatively coupled to the scanner device 17 and the detection unit 23 and is arranged for determining that an actual position of an element of the predetermined spatial pattern differs from an expected position of the element of the predetermined spatial pattern. The calibration unit 29 is coupled to the determining unit 27 and arranged for generating updated calibration data taking into account the difference, determined by the determining unit 27, between the actual position and the expected position, such that an updated actual position of the element of the predetermined spatial pattern corresponds to the expected position of the element of the predetermined spatial pattern. The control unit 31 is communicatively coupled to the scanner device 17 and the calibration unit 29 and arranged for controlling the scanner device 17 according to the updated calibration data.
As shown in Fig. 1 , the apparatus 1 also comprises a recoating device 33, comprising a supply unit 35 for supplying a layer of powdered material 7 to the bath of powdered material 7, and a levelling unit 37 which is arranged to be displaced along the surface level L of the bath of powdered material 7 for levelling the surface level L of the bath of powdered material 7.
A side view of an apparatus 401 according to the first aspect of the present disclosure is shown in Fig. 2. Elements of apparatus 401 that are identical or similar to elements of apparatus 1 are provided with the same reference numerals. In apparatus 401 the solidifying device 13 comprises the emitter unit 19 and a laser source 25 such that the laser source 25 is arranged for emitting the further electromagnetic radiation 21 and the electromagnetic radiation 15. In an embodiment of the apparatus 401 , the solidifying device 13 comprises a laser device arranged for emitting the beam of electromagnetic radiation 15 for melting the selective layer-part of the powdered material of the bath of powdered material 7, wherein the emitter unit 19 is integrated in the laser device. The laser device may further comprise a further laser source 25 arranged for emitting the further electromagnetic radiation 21.
In Fig. 3 is shown a side view of an apparatus 101 according to the first aspect of the present disclosure. Elements of apparatus 101 that are identical or similar to elements of apparatus 1 are provided with the same reference numerals.
In Fig. 3, the emitter unit 19 is arranged such that the optical path of the further electromagnetic radiation 21 , between the bath of powdered material 7 or the support 9 and the emitter unit 19, bypasses the scanner device 17. The detection unit 23 is arranged for detecting the further electromagnetic radiation 21 at the surface level L of the bath of powdered material 7 or the support 9 via the scanner device 17. The scanner device 17 is arranged for moving a detection area of the detection unit 23 along the surface level L or the support 9 for detecting, by the detection unit 23, the predetermined spatial pattern or at least an element or further element of the predetermined spatial pattern.
A side view of an apparatus 501 according to the first aspect of the present disclosure is shown in Fig. 4. Elements of apparatus 501 that are identical or similar to elements of apparatus 1 and/or 401 are provided with the same reference numerals. In apparatus 501 the emitter unit 19 comprises a further solidifying device 41 arranged for emitting the beam of further electromagnetic radiation 21 , wherein the beam of further electromagnetic radiation 21 is further arranged for melting a further selective layer-part of the powdered material of the bath of powdered material 7. The apparatus 501 further comprises a further scanner device 43 arranged for moving the beam of further electromagnetic radiation 21 along the surface level L of the bath of powdered material 7.
Fig. 5 shows a side view of an apparatus 601 according to the present disclosure. Elements of apparatus 601 that are identical or similar to elements of apparatus 1 , 401 and/or 501 are provided with the same reference numerals. The apparatus 601 comprises a yet further solidifying device 45 arranged for emitting a yet further beam of electromagnetic radiation 47 for melting a yet further selective layerpart of the powdered material of the bath of powdered material 7. The apparatus 601 further comprises a yet further scanner device 49 arranged for moving the yet further beam of electromagnetic radiation 47 along the surface level L of the bath of powdered material 7.
In Fig. 5, the detection unit 23 is further arranged such that an optical path of the yet further beam of electromagnetic radiation 47, between the bath of powdered material 7 or the support 9 and the detection unit 23, bypasses the yet further scanner device 49 for detecting the position of the yet further beam of electromagnetic radiation 47 at the surface level L of the bath of powdered material 7 or the support 9.
In a further embodiment, instead of arranging the detection unit 23 such that an optical path of the yet further beam of electromagnetic radiation 47, between the bath of powdered material 7 or the support 9 and the detection unit 23, bypasses the yet further scanner device 49 for detecting the position of the yet further beam of electromagnetic radiation 47 at the surface level L of the bath of powdered material 7 or the support 9, the detection unit 23 of the apparatus 601 may also be arranged for detecting a position of the yet further electromagnetic radiation 47 at the surface level L of the bath of powdered material 7 or the support 9 via the yet further scanner device 49.
The apparatus 1 may be used during a method 201 for manufacturing the object 3. During a step of emitting 203 of method 201 as shown in Fig. 6, the beam of the further electromagnetic radiation 21 is moved, by the scanner device 17, along the surface level L or the support 9 in the predetermined spatial pattern and during the step of detecting 205 of the method 201 , and during a step of detecting 205 of the method 201 , the detection unit 23 detects the predetermined spatial pattern. In the method 201 , a pattern of the emitted further electromagnetic radiation 21 on the surface level L of the bath of powdered material 7 or the support 9 the detected pattern may differ relative to the predetermined spatial pattern that is expected to be detected by the detection unit 23 and this could be an indication that the scanner device 17 needs to be recalibrated.
The method 201 as shown in Fig. 6 further comprises the steps of determining 207 that the actual position of the element of the predetermined spatial pattern differs from the expected position of the element of the predetermined spatial pattern, generating 209 updated calibration data taking into account the difference between the actual position and the expected position, such that the updated actual position of the element of the predetermined spatial pattern corresponds to the expected position of the element of the predetermined spatial pattern, controlling 211 the scanner device 17 according to the updated calibration data, supplying 213 the layer of powdered material 7 to the bath of powdered material 7, and levelling 215 the surface level L of the bath of powdered material 7.
In Fig. 6 the method 201 further comprises the steps of emitting 217 the further electromagnetic radiation 21 on the surface level L of the bath of powdered material 7 or the support 9 after the step of levelling 215 of the surface level L during production of the object 3, detecting 219 the further electromagnetic radiation 21 after the step of levelling 215 of the surface level L during production of the object 3, and determining 221 that the actual position of the element of the predetermined spatial pattern differs from the expected position of the element of the predetermined spatial pattern after the step of levelling 215 of the surface level L during production of the object 3.
The method 201 as shown in Fig. 6 also comprises the steps of generating 223 updated calibration data taking into account the difference between the actual position and the expected position after the step of levelling 215 of the surface level L during production of the object 3, and controlling 225 the scanner device 17 according to the updated calibration data after the step of levelling 215 of the surface level L during production of the object 3.
The apparatus 101 may be used during a method 301 for manufacturing the object 3. During a step of emitting 303 of method 301 as shown in Fig. 7, the emitter unit 19 provides the predetermined spatial pattern of the further electromagnetic radiation 21 on the surface level L or the support 9 and during the step of detecting 305 of the method 301 , the detection area of the detection unit 23 is moved, by the scanner device 17, along the surface level L or the support 9 for detecting the predetermined spatial pattern. In the method 301 , the detector unit 23 may detect via the scanner device 17 a pattern of the further electromagnetic radiation 21 that is different relative to the predetermined spatial pattern of the emitted further electromagnetic radiation 21 , provided by the emitter unit 19, on the surface level L of the bath of powdered material 7 or the support 9 and this could be an indication that the scanner device 17 needs to be recalibrated. Steps following after the step of detecting 205 of method 201 are identical or similar to steps following after the step of detecting 305 of method 301 and are provided with the same reference numerals increased by a hundred.

Claims

1. An apparatus (1 , 101 , 401 , 501 , 601) for producing an object (3) by means of additive manufacturing, the apparatus (1 , 101 , 401 , 501 , 601) comprising: a process chamber (5) for receiving a bath of powdered material (7) to produce the object (3); a support (9) for positioning the object (3) in relation to a surface level (L) of the bath of powdered material (7); a solidifying device (13) arranged for emitting a beam of electromagnetic radiation (15) for melting a selective layer-part of the powdered material of the bath of powdered material (7); a scanner device (17) arranged for moving the beam of electromagnetic radiation (15) along the surface level (L) of the bath of powdered material (7); an emitter unit (19) arranged for emitting further electromagnetic radiation (21), preferably a beam of further electromagnetic radiation (21), on the surface level (L) of the bath of powdered material (7) or the support (9); a detection unit (23) arranged for detecting a position of the further electromagnetic radiation (21), preferably the beam of further electromagnetic radiation (21), at the surface level (L) of the bath of powdered material (7) or the support (9) via the scanner device (17) or arranged such that an optical path of the further electromagnetic radiation (21), between the bath of powdered material (7) or the support (9) and the detection unit (23), bypasses the scanner device (17) for detecting the position of the further electromagnetic radiation (21) at the surface level (L) of the bath of powdered material (7) or the support (9); wherein the scanner device (17) is arranged for moving the beam of the further electromagnetic radiation (21) along the surface level (L) or the support (9) in a predetermined spatial pattern and wherein the detection unit (23) is arranged for detecting the predetermined spatial pattern and/or wherein the solidifying device (13) comprises a laser device arranged for emitting the beam of electromagnetic radiation (15) for melting the selective layer-part of the powdered material of the bath of powdered material (7), wherein the emitter unit (19) is integrated in the laser device.
2. The apparatus according to claim 1 , wherein the laser device comprises a further laser source (25) arranged for emitting the further electromagnetic radiation (21).
3. The apparatus (1 , 101 , 401 , 501 , 601) according to claim 1 or 2, wherein the apparatus (1 , 101 , 401 , 501 , 601) further comprises: a determining unit (27), communicatively coupled to the scanner device (17) and the detection unit (23), arranged for determining that an actual position of an element of the predetermined spatial pattern differs from an expected position of the element of the predetermined spatial pattern; a calibration unit (29), communicatively coupled to the determining unit (27), arranged for generating updated calibration data taking into account the difference, determined by the determining unit (27), between the actual position and the expected position, such that an updated actual position of the element of the predetermined spatial pattern corresponds to the expected position of the element of the predetermined spatial pattern; and a control unit (31), communicatively coupled to the scanner device (17) and the calibration unit (29), arranged for controlling the scanner device (17) according to the updated calibration data.
4. The apparatus (1 , 101 , 401 , 501 , 601) according to any one of the preceding claims, wherein the apparatus (1 , 101 , 401 , 501 , 601) is further provided with a recoating device (33) comprising:
- a supply unit (35) for supplying a layer of powdered material to the bath of powdered material (7); and
- a levelling unit (37) which is arranged to be displaced along the surface level (L) of the bath of powdered material (7) for levelling the surface level (L) of the bath of powdered material (7).
5. The apparatus (1 , 101 , 401 , 501 , 601) according to claim 4, wherein: the emitter unit (19) is arranged for emitting the further electromagnetic radiation (21) on the surface level (L) of the bath of powdered material (7) or the support (9) during or after the levelling, by the levelling unit (37), of the surface level (L), during production of the object (3); and/or the detection unit (23) is arranged for detecting the further electromagnetic radiation (21) during or after the levelling, by the levelling unit (37), of the surface level (L), during production of the object (3); and/or the determining unit (27) is arranged for determining that the actual position of the element of the predetermined spatial pattern differs from the expected position of the element of the predetermined spatial pattern during or after the levelling, by the levelling unit (37), of the surface level (L), during production of the object (3).
6. The apparatus (1 , 101 , 401 , 501 , 601) according to any one of the preceding claims, wherein the detection unit (23) comprises a camera (39) for detecting a position of the further electromagnetic radiation (21) at the surface level (L) of the bath of powdered material (7) or the support (9).
7. The apparatus (1 , 101 , 401 , 501 , 601) according to any one of the preceding claims, wherein at least one of the detection unit (23) and the emitter unit (19) is maintained in a predetermined position relative to the surface level (L) of the bath of powdered material (7), the support (9) and/or the process chamber (5).
8. The apparatus (501 , 601) according to any one of the preceding claims, wherein the emitter unit (19) comprises a further solidifying device (41) arranged for emitting the beam of further electromagnetic radiation (21), wherein the beam of further electromagnetic radiation (21) is further arranged for melting a further selective layerpart of the powdered material of the bath of powdered material (7) and wherein the apparatus (1 , 101 , 401 , 501 , 601) further comprises a further scanner device (43) arranged for moving the beam of further electromagnetic radiation (21) along the surface level (L) of the bath of powdered material (7).
9. The apparatus (601) according to any one of the preceding claims, wherein the apparatus (601) further comprises: a yet further solidifying device (45) arranged for emitting a yet further beam of electromagnetic radiation (47) for melting a yet further selective layer-part of the powdered material of the bath of powdered material (7); a yet further scanner device (49) arranged for moving the yet further beam of electromagnetic radiation (47) along the surface level (L) of the bath of powdered material (7); wherein the detection unit (23) is further arranged for detecting a position of the yet further electromagnetic radiation (47) at the surface level (L) of the bath of powdered material (7) or the support (9) via the yet further scanner device (49) or arranged such that an optical path of the yet further beam of electromagnetic radiation (47), between the bath of powdered material (7) or the support (9) and the detection unit (23), bypasses the yet further scanner device (49) for detecting the position of the yet further beam of electromagnetic radiation (47) at the surface level (L) of the bath of powdered material (7) or the support (9).
10. The apparatus (1 , 101 , 401 , 501 , 601) according to any one of the preceding claims, wherein a wavelength of the beam of electromagnetic radiation (15) and a wavelength of the further electromagnetic radiation (21) are different.
11. A method (201 , 301) of calibrating the apparatus (1 , 101 , 401 , 501 , 601) for producing an object (3) by means of additive manufacturing according to any one of the preceding claims, the method (201 , 301) comprising the steps of: emitting (203, 303), by the emitter unit (19), the further electromagnetic radiation (21) on the surface level (L) of the bath of powdered material (7) or the support (9); detecting (205, 305), by the detection unit (23), a position of the emitted further electromagnetic radiation (21) on the surface level (L) of the bath of powdered material (7) or the support (9).
12. The method (201) according to claim 12 using the apparatus (1 , 401 , 501 , 601) according to claim 1 , wherein, during the step of emitting (203), the beam of the further electromagnetic radiation (21) is moved, by the scanner device (17), along the surface level (L) or the support (9) in a predetermined spatial pattern and wherein, during the step of detecting (205), the detection unit (23) detects the predetermined spatial pattern.
13. The method (201 , 301) according to any one of the claims 11 to 12 using the apparatus (1 , 101 , 401 , 501 , 601) according to claim 4, wherein the method (201 , 301) further comprises the steps of: determining (207, 307), by the determining unit (27), that the actual position of the element of the predetermined spatial pattern differs from the expected position of the element of the predetermined spatial pattern; generating (209, 309), by the calibration unit (29), updated calibration data taking into account the difference, determined by the determining unit (27), between the actual position and the expected position, such that the updated actual position of the element of the predetermined spatial pattern corresponds to the expected position of the element of the predetermined spatial pattern; and controlling (211 , 311), by the control unit (31), the scanner device (17) according to the updated calibration data.
14. The method (201 , 301) according to any one of the claims 11 to 13 using the apparatus (1 , 101 , 401 , 501 , 601) according to claim 4, wherein the method (201 , 301) further comprises the steps of: supplying (213, 313), by the supply unit (35), the layer of powdered material to the bath of powdered material (7); and levelling (215, 315), by the levelling unit (37), the surface level (L) of the bath of powdered material (7).
15. The method (201 , 301) according to claim 14 using the apparatus (1 , 101 , 401 , 501 , 601) according to claim 5, wherein the method (201 , 301) further comprises the steps of: emitting (217, 317), by the emitter unit (19), the further electromagnetic radiation (21) on the surface level (L) of the bath of powdered material (7) or the support (9) during or after the step of levelling (215, 315), by the levelling unit (37), of the surface level (L), during production of the object (3); and/or detecting (219, 319), by the detection unit (23), the further electromagnetic radiation (21) during or after the step of levelling (215, 315), by the levelling unit (37), of the surface level (L), during production of the object (3); and/or determining (221 , 321), by the determining unit (27), that the actual position of the element of the predetermined spatial pattern differs from the expected position of the element of the predetermined spatial pattern during, before or after the step of levelling (215, 315), by the levelling unit (37), of the surface level (L), during production of the object (3).
16. The method (201 , 301) according to claim 15 using the apparatus (1 , 101 , 401 , 501 , 601) according to claim 3, wherein the method (201 , 301) further comprises the step of: generating (223, 323), by the calibration unit (29), updated calibration data taking into account the difference, determined during the step of determining (221 , 321), between the actual position and the expected position during or after the step of levelling (215, 315), by the levelling unit (37), of the surface level (L), during production of the object (3).
17. The method (201 , 301) according to claim 16 using the apparatus (1 , 101 , 401 , 501 , 601) according to claim 3, wherein the method (201 , 301) further comprises the step of: controlling (225, 325), by the control unit (31), the scanner device (17) according to the updated calibration data during or after the step of levelling (215, 315), by the levelling unit (37), of the surface level (L), during production of the object (3).
PCT/NL2023/050472 2022-09-21 2023-09-13 An apparatus for producing an object by powder bed additive manufacturing and a method of calibrating the apparatus WO2024063641A1 (en)

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