EP4225524A1

EP4225524A1 - Local selective irradiation of a working area with a non-circular beam shape

Info

Publication number: EP4225524A1
Application number: EP21782989.4A
Authority: EP
Inventors: Wilhelm Meiners; Sarah LEUCK
Original assignee: Trumpf Laser und Systemtechnik GmbH
Current assignee: Trumpf Laser und Systemtechnik Se
Priority date: 2020-10-09
Filing date: 2021-09-27
Publication date: 2023-08-16
Also published as: WO2022073785A1; US20230234135A1

Abstract

The invention relates to a planning device (15) for planning a locally selective irradiation of a working area (11) with an energy beam (7) in order to produce a component (3) from a powder material arranged in the working area (11) by means of the energy beam (7), the planning device (15) being designed to obtain a plurality of irradiation vectors (21) for irradiating a powder material layer arranged in the working area with the energy beam (7), the planning device (15) being designed to determine a vector orientation in a coordinate system in the working area (11) for at least one irradiation vector (21) of the plurality of irradiation vectors (21), and the planning device (15) being designed to specify, for the at least one irradiation vector (21), a beam orientation for a non-circular beam shape (18) of the energy beam (7) in the working area (11) relative to the vector orientation of the at least one irradiation vector (21).

Description

LOCALLY SELECTIVE RADIATION OF A WORKING AREA WITH A BEAM SHAPE DEVIATION FROM A CIRCULAR SHAPE

The invention relates to a planning device and a method for planning a locally selective irradiation of a work area with an energy beam

Computer program product for carrying out such a method, a

Manufacturing facility with such a planning facility, and a method for additively manufacturing a component from a powder material.

When additively manufacturing components from a powder material, an energy beam is typically selectively displaced to predetermined irradiation positions of a work area in order to locally solidify powder material arranged in the work area. In particular, this is repeated layer by layer in powder material layers arranged one after the other in the working area, in order finally to obtain a three-dimensional component made of solidified powder material.

The locally selective irradiation of the work area is planned in advance and/or ad hoc during manufacture, but typically before the actual irradiation of a layer of powder material. A planning device is provided for this purpose, which carries out this planning. It has been found that under certain conditions it can be advantageous, at least for certain areas of the component to be produced, to use a beam shape that deviates from a circular shape for the energy beam on the work area, for example to increase a build-up rate. However, this means that the corresponding beam shape, which is no longer rotationally symmetrical with respect to rotation at any desired angle, must be aligned relative to a displacement direction of the energy beam. conventional Planning facilities and procedures for planning the locally selective irradiation of the work area are not set up for this.

The object of the invention is to provide a planning device and a method for planning a locally selective irradiation of a work area with an energy beam, a computer program product for carrying out such a method, a manufacturing device with such a planning device, and a method for additively manufacturing a component from a powder material to create, wherein the disadvantages mentioned are at least reduced, preferably avoided.

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

The object is achieved in particular by creating a planning device for planning a locally selective irradiation of a work area with an energy beam in order to use the energy beam to produce a component from a powder material arranged in the work area, the planning device being set up to use a plurality of irradiation vectors for irradiating a layer of powder material arranged in the working area with the energy beam, the planning device being set up to determine a vector orientation in a coordinate system on the working area for at least one irradiation vector of the plurality of irradiation vectors, and the planning device being set up to for the at least one radiation vector, a beam alignment for a beam shape that deviates from a circular shape of the energy beam on the work area relative to the vector alignment of the at least one radiation source to specify gs vectors. In this way, it is possible to use a beam shape that deviates from a circular shape for the energy beam, at least in some areas, so that the associated advantages, in particular an increased build-up rate, can be achieved. In addition, a more stable process and/or an improved component quality, in particular a better surface quality, less distortion, and avoidance or reduction of cracks can be achieved.

The fact that the planning device is set up to receive the plurality of irradiation vectors includes, in particular, that the planning device has an interface or another suitable configuration in order to receive the irradiation vectors—preferably to be transmitted or received electronically, in particular in the form of a file or other machine-readable data, in particular wirelessly or with a cable. However, it also includes the planning device being set up to create or generate, in particular to calculate, the irradiation vectors. In particular, it is possible for a computer program to run on the planning device itself, by means of which the irradiation vectors can be calculated or generated in some other way. It is also possible for the radiation vectors to be entered into the planning device by a user, be it manually, by voice input, by gestures, or in some other suitable manner. The fact that the planning device is set up to receive the radiation vectors therefore means in particular that the radiation vectors can be made available or made accessible to the planning device in any way, this including that the radiation vectors can be generated in the planning device itself.

In particular, the planning device is set up to determine the vector alignment for the at least one radiation vector.

A beam shape of the energy beam on the work area is understood to mean, in particular, an intensity distribution of the energy beam on the work area, in particular on the powder material layer.

A jet shape deviating from the circular shape is preferably in particular a jet shape which has a first width along a first direction which is greater than a second width which the jet shape has along a second direction, the second direction being perpendicular to the first direction. The beam shape deviating from the circular shape is therefore in particular an elongated beam shape. The elongated beam shape is preferably aligned with the first width along the direction of displacement of the energy beam, ie along the vector alignment. According to a preferred embodiment, the beam shape, which deviates from the circular shape, has the shape of an ellipse. The elliptical beam shape is preferably aligned with its large semi-axis along the vector alignment.

The planning device is set up in particular to define the beam alignment relative to the vector alignment for the at least one irradiation vector. The beam alignment is given in particular by an angle that the beam shape encloses with a specific axis of the coordinate system on the work area. In contrast, the term "beam orientation" used in the following describes an orientation of a beam shape that is not symmetrical along the beam alignment along the direction defined by the beam alignment, i.e. the fact whether the beam shape is "forward" or "backward". - is oriented - in particular with a view to a displacement direction of the beam shape.

The fact that the planning device is set up to specify, in particular to define, the beam alignment for the at least one irradiation vector means in particular that the planning device is set up to generate a control variable, in particular an angle, for the at least one radiation vector for controlling an optical device, wherein the beam shape of the energy beam can be aligned on the work area by means of the optical device.

It is possible that the planning device is set up to determine a vector orientation for each irradiation vector of the plurality of irradiation vectors. This is advantageous in particular when all the radiation vectors are assigned a beam shape that deviates from the circular shape, or when the beam shape that deviates from the circular shape is permanently specified for all the radiation vectors. However, it is also possible for the planning device to be set up to determine the vector orientation for a number of the irradiation vectors, the number being smaller than the majority of the irradiation vectors. In particular, it is possible for the planning device to be set up to determine the vector orientation only for those irradiation vectors that are also assigned a beam shape that deviates from the circular shape. In this way, it is advantageously possible in particular to save computing power and possibly also memory space, since there is no need to determine the vector orientation for those irradiation vectors to which a circular beam shape is assigned.

The planning device is preferably designed in particular as a build processor, in particular external to a manufacturing device, or as a control device, in particular as an internal control device, of a manufacturing device for additively manufacturing a component from a powder material. Under a build processor is to be understood in particular a device that generates a data set or a file with data that can be passed to a control device of a manufacturing facility, so that the Manufacturing facility can additively manufacture a component from a powder material based on the data. In particular, if the planning device is designed as a build processor, it generates the irradiation vectors itself in a preferred embodiment. If, on the other hand, the planning device is designed as a control device of a manufacturing facility, it preferably receives the irradiation vectors from a build processor, in particular as a data set and/or in the form of a File. However, the planning device can also be provided partly in the build processor and partly in the control device of the manufacturing device. In particular, steps of the method according to the invention for planning the locally selective irradiation described in connection with the planning device or one or more embodiments of this method can be carried out in the build processor, in the control device, or partly in the build processor and partly in the control device will.

In particular, the planning device is preferably selected from a group consisting of a computer, in particular a personal computer (PC), a mobile computing device, for example a tablet or smartphone, a plug-in card or control card, and an FPGA board. In a preferred embodiment, the planning device is an RTC6 control card from SCANLAB GmbH, in particular in the version currently available on the date determining the seniority of the present property right. However, the planning device can also be implemented as a service provider, ie in particular a server, or as a plurality of interconnected computing devices, in particular as a network or part of a network, in particular as a cloud or part of a cloud.

Additive or generative manufacturing or production of a component is understood to mean in particular a layered construction of a component from powder material - powder material layer for powder material layer - in particular a powder bed-based method for producing a component in a powder bed, in particular a manufacturing method that is selected from a group consisting selective laser sintering, selective plastic laser sintering, laser metal fusion (LMF), direct metal laser melting (DMLM), direct metal laser sintering (DMLS), Laser Net Shaping Manufacturing (LNSM), Laser Engineered Net Shaping (LENS), and - in particular selective - Electron Beam Melting (EBM). An energy beam is generally understood to mean directed radiation that can transport energy. This can generally involve particle radiation or wave radiation. In particular, the energy beam propagates through the physical space along a propagation direction and thereby transports energy along its propagation direction. In particular, it is possible by means of the energy beam to deposit energy locally in the work area.

In a preferred embodiment, the energy beam is an electron beam or an optical working beam. An optical working beam is to be understood in particular as directed electromagnetic radiation, continuous or pulsed, which is suitable in terms of its wavelength or a wavelength range for the additive or generative manufacturing of a component from powder material, in particular for sintering or melting the powder material. In particular, an optical working beam means a laser beam that can be generated continuously, pulsed or modulated. The optical working beam preferably has a wavelength or a wavelength range in the visible electromagnetic spectrum or in the infrared electromagnetic spectrum, or in the overlap region between the infrared range and the visible range of the electromagnetic spectrum.

A working area is understood to mean in particular an area, in particular a plane or surface, in which the powder material layer is arranged and which is locally irradiated with the energy beam in order to locally solidify the powder material. In particular, the powder material is sequentially arranged in layers in the work area and is locally irradiated with the energy beam in order to produce a component—layer by layer.

The fact that an energy beam is applied locally to the work area means in particular that the energy beam is not applied to the entire work area globally - neither instantaneously nor sequentially - but rather that the work area is covered in places, in particular at individual, connected or separate locations, with the Energy beam is applied, wherein the energy beam is shifted in particular by means of the scanner device within the work area. The fact that the energy beam is applied selectively to the work area means in particular that the energy beam is applied to the work area at selected, predetermined points or locations or in selected, predetermined areas. The working area is in particular a layer of powder material or a preferably contiguous area Powder material layer, which / which can be reached by the energy beam using the scanner device, that is, it includes in particular those points, locations or areas of the powder material layer that can be acted upon by the energy beam.

An irradiation vector is understood to mean, in particular, a specific section in the work area along which a continuous, in particular linear displacement of the energy beam is carried out, with the section having a specific length, specific direction of displacement, possibly at least in some areas a specific curvature or a specific one, from a straight line deviating path, and having a specific orientation of displacement. The irradiance vector thus preferably includes direction or orientation as its vector orientation, length as its vector length, and orientation - i.e. along the "forward" or "backward" orientation - of displacement as its vector orientation.

The fact that the displacement takes place continuously means in particular that it takes place without dropping or interrupting the energy beam, in particular without a jump. The fact that the irradiation takes place linearly means in particular that it takes place along a straight line.

Such an irradiation vector is preferably represented at least—preferably precisely—by specifying a starting point and an end point in the coordinate system spanned over the working area. The planning device is set up in particular to determine, in particular to calculate, from the starting point and the end point of a radiation vector its vector orientation and preferably also at least one other variable selected from its vector length and its vector orientation. In particular, if a radiation vector has a curvature at least in regions or approximates a curved path by piecewise stringing together of linear sections, it is possible for the radiation vector to be described by at least one further path parameter, for example a plurality of intermediate points between the starting point and the end point. In particular, it is also possible for a radiation vector to be defined by a plurality of connected partial vectors.

The vector orientation is in particular an angle which the irradiation vector encloses—at least locally—with a specific axis of the coordinate system. As already explained, the vector orientation includes the—at least local—direction of displacement of the energy beam along the irradiation vector, or to put it another way Ask which of the points defining the radiation vector is the starting point and which is the ending point for the displacement.

A development of the invention provides that the planning device is set up to specify a beam shape of the energy beam for each radiation vector of the plurality of radiation vectors, in particular to assign a beam shape to each radiation vector of the plurality of radiation vectors. It is fundamentally possible that the same beam shape is assigned to each irradiation vector. However, it is also possible to assign different beam shapes to different irradiation vectors, which can be advantageous in particular for increasing the flexibility of production. In addition, it is possible in this way to select optimum production parameters, in particular depending on specific local conditions. In particular, the planning device is preferably set up to specify, in particular assign, either a circular beam shape or a beam shape that deviates from the circular shape of the energy beam for each radiation vector of the plurality of radiation vectors.

Alternatively or additionally, the planning device is set up to specify, in particular to allocate, an energy input parameter of the energy beam for each irradiation vector of the plurality of irradiation vectors. The at least one energy input parameter is preferably selected from a group consisting of a beam power and a displacement speed of the energy beam on the work area, in particular within a radiation vector from its starting point to its end point. This proves to be particularly advantageous when the same beam shape is assigned to each irradiation vector. It is then possible, in particular, to take different local conditions into account by selecting different energy input parameters in each case.

According to a development of the invention, it is provided that the planning device is set up to determine the vector orientation of at least one radiation vector of the plurality of radiation vectors. The planning device is preferably also set up to specify a beam orientation for the at least one irradiation vector—relative to the vector orientation—for the beam shape assigned to the at least one irradiation vector. In this way, a beam shape can also be used that is not symmetrical in the direction of the vector alignment, so that the orientation of the beam shape relative to the vector orientation must be specified in order to determine the position of the beam shape, especially with regard to the direction of displacement of the Energy beam, definitely to set. It is thus possible to use beam shapes that are not symmetrical along the vector alignment. This can further increase the flexibility of production.

The planning device is preferably set up to determine the vector orientation for that irradiation vector or those irradiation vectors for which the vector orientation is also determined. These are in particular those irradiation vectors for which a beam shape deviating from the circular shape is also used. In a preferred embodiment, it is possible for the planning device to be set up to determine a vector orientation only for those irradiation vectors for which a beam shape that is not symmetrical in the direction of the vector orientation is also used.

According to a development of the invention, it is provided that the planning device is set up to assign a different beam shape to at least two radiation vectors of the plurality of radiation vectors depending on at least one vector parameter, with the at least one vector parameter preferably being selected from a group consisting of of: a location of the exposure vector on the work area, an assignment of the exposure vector to a particular vector group, and a vector length of the exposure vector.

Alternatively or additionally, the planning device is set up to assign a different energy input parameter depending on the at least one vector parameter to at least two irradiation vectors of the plurality of irradiation vectors.

If the location of the irradiation vector on the work area is used as the vector parameter, this allows local conditions to be taken into account when selecting the beam shape or the energy input parameter. Taking into account the assignment of the irradiation vector to a specific vector group as a vector parameter makes it possible to advantageously take into account local production conditions or conditions of the component being produced, in particular also conditions of the three-dimensional geometry of the component being produced. Taking the vector length into account as a vector parameter is advantageous, since a beam shape that deviates from the circular shape can be disadvantageous in the case of comparatively short radiation vectors, especially if an elongated length of the beam shape is approximately the same as the vector length of the radiation vector. It then proves to be particularly advantageous to assign a circular beam shape corresponding to comparatively short radiation vectors. The one described The procedure is particularly suitable for an embodiment of the planning device as a control device of a production device or an implementation of the planning device in such a control device.

The assignment of a radiation vector to a specific vector group means in particular whether the radiation vector is assigned as a contour vector to a component contour, whether the radiation vector is assigned to a filigree component structure, or whether the radiation vector is assigned to a support structure for the component to be manufactured, a volume area or "in skin ' area, an overhang area or 'down skin' area, or a top layer area or 'up skin' area of the layer of powder material. Different production conditions arise in the corresponding areas, which can advantageously be taken into account accordingly through a suitable selection of the beam shape and/or the energy input parameter. For example, for certain critical structures, for example for certain support structures, a reduced spatial and temporal input of energy is required in order to avoid local overheating, for example. In this case, a circular beam shape can be advantageous compared to a beam shape that deviates from the circular shape. In this respect, the planning device is particularly preferably set up to identify corresponding component areas, in particular critical component areas, to assign the irradiation vectors to the corresponding vector groups, and to select a suitable beam shape and/or a suitable energy input parameter for each of the irradiation vectors.

An overhang area is in particular an area within a powder material layer below which, ie in underlying powder material layers, there is non-solidified powder material. Such an overhang is also referred to as "down skin". A top layer region is in particular a region within a powder material layer above which, ie in overlying powder material layers, there is non-solidified powder material. Such a top layer area is also referred to as "up skin". This term also refers to the uppermost layer of powder material, which still comprises solidified powder material, ie a roof surface or uppermost surface of the component. A volume area is in particular an area within a powder material layer which is surrounded on all sides in the finished component by solidified powder material, in particular within the powder material layer but also above and below the powder material layer just processed. Such an area is also referred to as an “in skin” area. According to one development of the invention, it is provided that the planning device is set up to define a plurality of irradiation areas on the work area and to assign the radiation vectors to the irradiation areas, with the planning device being set up to specify a beam shape of the energy beam for each irradiation area of the plurality of irradiation areas , and to define a division of the irradiation areas depending on a vector length of the irradiation vectors in the irradiation areas. This procedure is particularly suitable when the planning device is designed as a build processor. It is then possible, for example, to generate or specify strip-shaped irradiation areas, with each irradiation area being assigned a specific beam shape. If the beam shape is then to be changed as a function of the vector length, this is possible in a particularly simple manner if a new irradiation area is defined from a certain limit vector length, in particular towards shorter irradiation vectors, or an existing irradiation area is divided into a first area with longer irradiation vectors and a second area with shorter irradiation vectors. However, the irradiation areas can, for example, also be smaller rectangular or square areas, for example in the manner of chessboard fields.

The fact that the planning device is set up to define a plurality of irradiation areas in the work area and to assign the radiation vectors to the irradiation areas means in particular that the planning device can be set up to assign existing radiation vectors to different irradiation areas. Alternatively or additionally, the planning device can be set up to generate new irradiation vectors in different irradiation areas.

An irradiation area is in particular sequentially covered with a large number of irradiation vectors. In particular, a strip-shaped irradiation area is preferably sequentially swept over with a multiplicity of irradiation vectors aligned in the width direction of the irradiation area, offset from one another in the longitudinal direction of the irradiation area or arranged next to one another. In this case, adjacent irradiation vectors can be aligned in particular parallel or antiparallel to one another.

According to one development of the invention, it is provided that the planning device is set up to calculate at least one contour distance of the at least one for at least one irradiation vector of the plurality of irradiation vectors radiation vector to a contour line of a component contour of a component layer to be produced on the powder material layer in the working area as a function of at least one distance parameter, the at least one distance parameter being selected from a group consisting of: the beam shape assigned to the at least one irradiation vector, and a contour angle that the at least one irradiation vector encloses with the contour line. The planning device is preferably set up to specify the at least one contour distance as a function of the two distance parameters of the aforementioned group. The planning device is preferably set up in such a way that an operator can parameterize the at least one contour distance or specify conditions for specifying the at least one contour distance, for example in the form of a table or a characteristic map.

A component contour is understood here as a boundary line or border line of a component layer or of a region of the component layer.

A component layer is understood here to mean a layer of the resulting component that is still to be produced or has already been produced in the powder material layer arranged there in the work area, i.e. in particular - after the end of the irradiation of the powder material layer - those areas of the same in which the powder material solidifies by the energy beam, in particular sintered or fused. As part of the additive manufacturing process, the component is successively built up component layer by component layer from the layers of powder material arranged one on top of the other.

The at least one contour distance is preferably a distance that a center point or focus of the beam shape has at least to the contour line. In particular, the contour distance can be given from an intensity maximum of the beam shape. Alternatively, the contour distance can be given by a predetermined border or level line, which runs, for example, at a predetermined percentage of the maximum intensity. In principle, a large number of definitions for the contour distance are possible, which, however, have the same physical meaning as a result. Thus, the contour distance determines in particular where the at least one irradiation vector has to start or end in relation to the contour line. The contour distance thus depends in particular on the expansion of the jet shape. In particular, the contour distance is advantageously selected as a function of the specific beam shape, it being selected in particular as a function of a deviation of the beam shape from the circular shape. If the beam shape deviates from the circular shape, a suitable one is hanging Selection of the contour distance depends in particular on the contour angle that the at least one irradiation vector and thus also the beam shape itself encloses with the contour line. It is possible for two contour distances to be determined for an irradiation vector, in particular a first contour distance along the vector orientation and a second contour distance perpendicular to the vector orientation. Since the beam shape is preferably elongated along the vector orientation, the first contour distance is preferably chosen to be larger than the second contour distance. If, however, the beam shape is not symmetrical along the vector alignment, different contour distances are preferably selected depending on the beam shape—possibly in particular more than two contour distances—whereby values of the different contour distances can then also depend in particular on the beam orientation.

According to a development of the invention, the planning device is set up to carry out the determination of the vector alignment and the specification of the beam alignment for each component layer of a plurality of the component layers to be produced one after the other in the work area. In this context, it can prove to be particularly advantageous if the vector alignment, and thus in particular at the same time also the beam alignment, varies from component layer to component layer. In a particularly simple configuration, it is possible for the irradiation vectors or irradiation areas to be rotated by a predetermined angle with the irradiation vectors from component layer to component layer. The planning device is then set up in particular to rotate the beam alignment accordingly.

According to a development of the invention, it is provided that the planning device is set up to specify a number of displacements of the energy beam along a contour line of a component contour of a component layer to be produced on the powder material layer in the working area as a function of at least one contour travel parameter, the at least one contour travel parameter is selected from a group consisting of: the beam shape assigned to at least one irradiation vector adjoining the contour line, and a contour angle which the at least one irradiation vector adjoining the contour line encloses with the contour line. According to a preferred embodiment, the planning device is set up to specify the number of displacements of the energy beam along the contour line as a function of the two contour travel parameters of the aforementioned group. A shift in the energy beam, also known as contouring along a contour line is carried out in particular in order to smooth the contour, which is less precisely defined due to the discrete irradiation vectors ending in the area of the contour line compared to inner component areas, and to eliminate any unevenness and/or porosities that have arisen there. Depending on the contour angle and the beam shape, and in particular also dependent on the contour distance, which in turn depends on these parameters, the contour line is better or less well defined. Depending on this, a larger number or a smaller number of contour travels are then required in order to obtain a high-quality component contour. In particular, the number of contour runs is selected to be larger when the contour distance is larger, and the number of contour runs is selected to be smaller when the contour distance is smaller.

In particular, in the case of a contour distance that is smaller than a predetermined limit contour distance, no additional contour travels are carried out in addition to a number of contour travels that are provided anyway, while in the case of a contour distance that is greater than or equal to the predetermined limit contour distance , additional contour runs can be carried out. Alternatively or additionally, no additional contour runs are preferably carried out in the area of a circular jet shape, while additional contour runs are carried out in areas where the jet shape deviates from the circular shape.

According to a further development of the invention, it is provided that the planning device is set up to assign each energy beam of a plurality of energy beams a specific beam shape—in particular fixed—and to assign one energy beam of the plurality of energy beams with a matching beam shape to the irradiation vectors. In this way, different beam shapes can be realized very easily, especially in a so-called multi-laser machine. In this case, it is not necessary to control an optical device that can be adjusted or controlled in some other way in order to change the beam shape, but only to use a different energy beam. Optionally, adjustable and/or controllable optical devices can even be dispensed with entirely.

If, on the other hand, only one energy beam is available, the beam shape is preferably switched by suitably controlling a suitable optical device or a corresponding optical element or—in a particularly simple embodiment—moving it in or out into a beam path of the energy beam as required. The object is also achieved by creating a method for planning a locally selective irradiation of a work area with an energy beam in order to use the energy beam to produce a component from a powder material arranged in the work area, wherein for at least one irradiation vector of a plurality of irradiation vectors for irradiation a powder material layer arranged in the working area with the energy beam, a vector orientation in a coordinate system on the working area is determined, and wherein for the at least one irradiation vector a beam orientation for a beam shape of the energy beam deviating from a circular shape on the working area relative to the vector Alignment of the at least one radiation vector is specified. In connection with the method, the advantages that have already been explained in connection with the planning device are realized in particular.

The method preferably comprises at least one method step, preferably a plurality of method steps, which have been described explicitly or implicitly in connection with the planning device, in particular in the form of preferred configurations or devices of the planning device.

According to a preferred embodiment, it is possible for the planning or at least partial steps of the planning of the locally selective irradiation to be carried out at the start of production, in particular before a first layer of powder material is irradiated with the energy beam. Alternatively, it is preferably possible for the planning or at least partial steps of the planning to be carried out layer by layer during the irradiation of a layer of powder material with the energy beam for the subsequent layer of powder material. Alternatively, it is preferably possible for the planning or at least partial steps of the planning to be carried out during a powder application to produce a new powder material layer over a powder material layer that has just been irradiated. Finally, it is preferably also possible for the planning or at least partial steps of the planning, in particular the specification of the beam alignment or the determination of the vector alignment and the specification of the beam alignment, in real time during the irradiation of a powder material layer for the powder material layer just irradiated is carried out.

The object is also achieved by creating a manufacturing device for the additive manufacturing of components from a powder material. The manufacturing device has a beam generating device that is set up to generate an energy beam. In addition, the manufacturing device has a scanner device that is set up to locally selectively irradiating a work area with the energy beam in order to use the energy beam to produce a component from the powder material arranged in the work area. Furthermore, the manufacturing device has an optics device that is set up to shape and align the energy beam. Finally, the manufacturing device has a control device that is operatively connected to the scanner device and set up to control the scanner device. The control device is also operatively connected to the optics device in order to control the controllable optics device. The control device has a planning device according to the invention or a planning device according to one or more of the exemplary embodiments described above, or is designed as a planning device according to the invention or as a planning device according to one or more of the exemplary embodiments described above. In connection with the production facility, there are in particular the advantages that have already been explained above in connection with the planning facility and the planning method.

The beam generating device is preferably designed as a laser. The energy beam is thus advantageously generated as an intensive beam of coherent electromagnetic radiation, in particular coherent light. In this respect, irradiation preferably means exposure. Alternatively, according to a preferred embodiment, the beam generating device is designed as an electron beam gun. The energy beam is thus advantageously generated as an electron beam.

The scanner device preferably has at least one scanner, in particular a galvanometer scanner, piezo scanner, polygon scanner, MEMS scanner, capacitor plates, and/or a working head or processing head that can be displaced relative to the work area. The scanner devices proposed here are particularly suitable for shifting the energy beam within the working area between a plurality of irradiation positions.

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

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

The production facility is preferably set up for selective laser sintering. Alternatively or additionally, the production facility is set up for selective laser melting. Alternatively, the manufacturing facility is preferably set up for selective electron beam melting. These configurations of the production facility have proven to be particularly advantageous.

The optics device is preferably set up to increase a first width of the energy beam along a predeterminable direction, in particular along the vector orientation, relative to a second width of the energy beam perpendicular to the predeterminable direction. According to a preferred embodiment, the optics device is designed as an astigmatic optics or has an astigmatic optics, for example at least one cylindrical lens, preferably two cylindrical lenses. According to another preferred embodiment, the optics device is designed as a non-astigmatic optics or has a non-astigmatic optics. In a particularly preferred manner, such a non-astigmatic optic has at least one anamorphic prism, preferably two anamorphic prisms. Preferably, the optics device also has an—in particular controllable—actuating device that is set up to align the beam shape of the energy beam, with the actuation device being set up in particular to rotate at least one optical element of the optics device. In a preferred embodiment, the adjusting device is designed as a rotary table, in particular as a controllable rotary table, or the like.

However, according to a preferred embodiment, the optics device can also have at least one controllable deflector element, which is set up to generate a quasi-stationary intensity distribution in the local beam-forming area by dynamic scanning of a local beam-forming area and in this way to locally form the energy beam and the thus generated align quasi-stationary beam shape. In a preferred embodiment the optical device can be designed as an acousto-optical deflector or as a diffractive optical element.

The object is also achieved by creating a computer program product which has machine-readable instructions, on the basis of which a method according to the invention for planning or a method according to one or more of the embodiments described above is carried out on a computing device, in particular a planning device or a control device, if the computer program product runs on the computing device. In connection with the computer program product, there are in particular the advantages that have already been explained in connection with the planning device, the method for planning and the production device.

Finally, the object is also achieved by creating a method for additively manufacturing a component from a powder material using a manufacturing device according to the invention or a manufacturing device according to one or more of the exemplary embodiments described above, wherein a working area is locally selectively irradiated with the energy beam in order to energy beam to produce the component from the powder material arranged in the working area, with a layer of powder material arranged in the working area being exposed to the energy beam in the form of a plurality of irradiation vectors, with a beam shape of the energy beam deviating from a circular shape being applied to the working area for at least one irradiation vector of the plurality of Irradiation vectors is aligned relative to a vector alignment of the at least one irradiation vector in a coordinate system on the work area. In connection with the method for additive manufacturing, the advantages that were explained above in connection with the planning device, the method for planning, the manufacturing device and the computer program product are realized in particular.

If all irradiation vectors for a layer of powder material to be irradiated have the same vector orientation, and if the vector orientation is only rotated from powder material layer to powder material layer by a certain angle, then the beam orientation only needs to be adjusted once before irradiating each one powder material layer. This can be carried out, for example, by suitable rotation of the optics device or an optical element of the optics device. On the other hand, if a layer of powder material has different irradiation vectors with different Associated with vector alignments, it also requires a change in the beam alignment, in particular a suitable rotation of the optics device or the corresponding optical element, within or during the irradiation of the affected powder material layer.

A laser is preferably used as the beam generating device. Alternatively, an electron beam gun is preferably used.

The component is preferably manufactured by means of selective laser sintering and/or selective laser melting. Alternatively, the component is manufactured by means of - in particular selective - electron beam melting.

In particular, a metallic or ceramic powder can preferably be used as the powder material.

According to one development of the invention, it is provided that a different beam shape is used for at least two radiation vectors of the plurality of radiation vectors depending on at least one vector parameter, with the at least one vector parameter preferably being selected from a group consisting of: a location the exposure vector on the work area, an assignment of the exposure vector to a specific vector group, and a vector length of the exposure vector.

Alternatively or additionally, it is preferably provided that for at least two irradiation vectors of the plurality of irradiation vectors, a different energy input parameter is used depending on at least one vector parameter, with the at least one vector parameter preferably being selected from a group consisting of: a location of the exposure vector on the work area, an assignment of the exposure vector to a specific vector group, and a vector length of the exposure vector.

According to a development of the invention, it is provided that the energy beam is displaced several times along a contour line of a component contour of a component layer to be produced on the powder material layer in the working area, with a number of displacements of the energy beam along the contour line being selected as a function of at least one contour travel parameter , wherein the at least one contour travel parameter is selected from a group consisting of: the beam shape associated with at least one irradiation vector adjoining the contour line, and a contour angle which the at least one irradiation vector adjoining the contour line encloses with the contour line. The number of displacements of the energy beam along the contour line is preferably selected as a function of both contour travel parameters of the previously defined group.

The method preferably comprises at least one method step, preferably a plurality of method steps, which have been described explicitly or implicitly in connection with the planning device, in particular in the form of preferred configurations or devices of the planning device, in connection with the method for planning, or in connection with the production device .

The invention also includes a computer program product which has machine-readable instructions, on the basis of which a method according to the invention for additively manufacturing a component or a method according to one or more of the embodiments described above is carried out on a computing device, in particular a control device of a manufacturing device, if the computer program product the computing device is running. In connection with the computer program product, there are in particular the advantages that have already been explained in connection with the planning device, the planning method, the production device and the method for additive manufacturing.

The invention is explained in more detail below with reference to the drawing. show:

FIG. 1 shows a schematic representation of an exemplary embodiment of a manufacturing device for the additive manufacturing of components from a powder material with an exemplary embodiment of a planning device;

FIG. 2 shows a schematic representation of a first embodiment of a method for planning a locally selective irradiation of a work area, and

FIG. 3 shows a schematic representation of a second embodiment of such a method. 1 shows an exemplary embodiment of a manufacturing device 1 for the additive manufacturing of a component 3 from a powder material. The manufacturing device 1 has a beam generating device 5 which is set up to generate an energy beam 7 . The beam generating device 5 is preferably designed as a laser or has a laser, and the energy beam 7 is preferably a laser beam accordingly. However, the energy beam 7 can in particular also be an electron beam. In this case, the beam generating device 5 is designed as an electron beam gun.

The production device 1 also has a scanner device 9 which is set up to locally and selectively irradiate a work area 11 with the energy beam 7 in order to use the energy beam 7 to produce the component 3 from the powder material arranged in the work area 11 . The scanner device 9 preferably has a controllable scanner 12 for the energy beam 7, for example a galvo scanner.

The production device 1 also has a control device 13 which is operatively connected to the scanner device 9 and set up to control the scanner device 9 , in particular to move the energy beam 7 within the work area 11 .

The control device 13 is designed here as a planning device 15 . Alternatively, it is possible for the control device 13 to have a planning device 15 . However, it is also possible for the planning device 15 to be provided separately from the production device 1, for example as a build processor or as a cloud application.

The planning device 15 is set up to plan the locally selective irradiation of the work area 11 with the energy beam 7 .

The production device 1 also has an optical device 17 . The optical device 17 has an optical system 19, in particular an astigmatic optical system, preferably with at least one cylindrical lens, or a non-astigmatic optical system, preferably with at least one anamorphic prism. The optics device 17 is set up in particular by the optics 19 in order to shape the energy beam 7 and align it along a parameterizable direction, in particular along a direction of displacement of the energy beam 7 shown here by an arrow P within the working area 11 . However, according to a preferred embodiment, the optics device 17 can also have at least one controllable deflector element, which is set up to dynamically scan a local beam shape area to generate a quasi-stationary intensity distribution in the local beam shape area and in this way to shape the energy beam locally and to align the generated quasi-stationary beam shape. In a preferred embodiment, the optics device 17 can be designed as an acousto-optical deflector or as a diffractive optical element.

The optics device 17 is set up in particular to increase a first width B1 of the energy beam 7 along the displacement direction illustrated by the arrow P relative to a second width B2 of the energy beam 7 perpendicular to the displacement direction, in particular to generate an elliptical energy beam 7.

The control device 13 is operatively connected to the optics device 17 in order to control the controllable optical device 17 , in particular a controllable actuating device 16 . The adjusting device 16 is set up in particular to rotate the energy beam 7 about its optical axis or beam axis.

The planning device 15 is set up to obtain a plurality of irradiation vectors 21 (see FIGS. 2 and 3) for irradiating a layer of powder material arranged in the working area 11 with the energy beam 7 . The planning device 15 determines a vector orientation in a coordinate system on the work area 11 for at least one irradiation vector 21 of the plurality of irradiation vectors 21, and it gives a beam orientation for the at least one irradiation vector 21 of the plurality of irradiation vectors 21 for a shape that deviates from a circular shape Beam shape of the energy beam 7 on the work area 11 relative to the vector orientation of the at least one irradiation vector 21.

The planning device 15 preferably specifies a beam shape of the energy beam 7 and/or an energy input parameter of the energy beam 7, in particular a beam power and/or a displacement speed, for each irradiation vector 21.

In particular for irradiation vectors 21 in which the associated beam shape is not symmetrical along the vector orientation, the planning device 15 also determines a vector orientation and specifies a beam orientation for the associated beam shape relative to the vector orientation. The planning device 15 preferably assigns a different beam shape and/or a different energy input parameter to at least two irradiation vectors 21 depending on at least one vector parameter. The at least one vector parameter can be a location of the radiation vector 21 on the work area 11 . Alternatively or additionally, the vector parameter can be an assignment of the irradiation vector 21 to a specific vector group. Alternatively or additionally, the vector parameter can be a vector length of the irradiation vector 21 .

The planning device 15 preferably carries out the determination of the vector alignment and the specification of the beam alignment for each component layer of a plurality of component layers to be produced one after the other in the work area 11 .

If the production device 1 has a plurality of energy beams 7 , the planning device 15 preferably assigns a specific beam shape to each energy beam 7 . It then assigns one energy beam 7 of the plurality of energy beams 7 with a matching beam shape to the radiation vectors 21 so that the radiation vectors 21 are each processed with that energy beam 7 that has the appropriate beam shape assigned to the respective radiation vector 21 .

Finally, the manufacturing device 1 preferably carries out a method for manufacturing the component 3 according to the plan created by the planning device 15 .

Fig. 2 shows a schematic representation of a first embodiment of a method for planning a locally selective irradiation of the work area 11.

Two contour lines 22 of a component contour 24 are shown here, namely a first contour line 22.1 and a second contour line 22.2, as well as a radiation vector 21, to which a beam shape 18 deviating from the circular shape is assigned. Two contour distances are specified for the irradiation vectors 21, namely a first contour distance a from the first contour line 22.1, and a second contour distance b from the second contour line 22.2. The contour distances a, b are selected as a function of the beam shape 18 and a contour angle that the irradiation vector 21 has in relation to the respective contour line 22 . The first contour spacing a for the first contour line 22.1 running parallel to the radiation vector 21 is selected to be smaller than the second contour spacing b for the second contour line 22.2 running perpendicular to the radiation vector 21. Fig. 3 shows a schematic representation of a second embodiment of the method for planning a locally selective irradiation of the work area 11.

The planning device 15 preferably defines a plurality of irradiation areas 23 on the work area 11 and assigns the irradiation vectors 21 to the irradiation areas 23 . The planning device 15 specifies a beam shape 18 of the energy beam 7 for each irradiation area 23 and defines a division of the irradiation areas 23 depending on a vector length of the irradiation vectors 21 in the irradiation areas 23 . In this respect, a first irradiation area 23.1 and a second irradiation area 23.2 are shown here, with an area limit 25 between the irradiation areas 23 being selected on the basis of a predetermined limit vector length. The first irradiation area 23.1 comprises longer irradiation vectors 21, while the second irradiation area 23.2 comprises shorter irradiation vectors 21. An elongated beam shape 18 deviating from the circular shape is assigned to the first irradiation area 23.1, and a circular beam shape 18 is assigned to the second irradiation area 23.2.

The energy beam 7 is preferably displaced several times along the contour lines 22 . A number of displacements of the energy beam 7 along the contour lines 22 is preferably selected as a function of at least one contour travel parameter. In particular, the number of shifts is preferably selected as a function of the beam shape 18 of the radiation vectors 21 adjoining the respective contour line 22 . Alternatively or additionally, preferably additionally, the number of displacements is selected as a function of the contour angle that the adjacent irradiation vectors 21 enclose with the respective contour line 22 .

Claims

EXPECTATIONS

1. Planning device (15) for planning a locally selective irradiation of a work area (11) with an energy beam (7) in order to use the energy beam (7) to produce a component (3) from a powder material arranged in the work area (11), the The planning device (15) is set up to obtain a plurality of irradiation vectors (21) for irradiating a powder material layer arranged in the work area (11) with the energy beam (7), the planning device (15) being set up to obtain at least one irradiation vector ( 21) of the plurality of irradiation vectors (21) to determine a vector orientation in a coordinate system on the work area (11), and wherein the planning device (15) is set up to determine, for the at least one irradiation vector (21), a beam orientation for a beam shape (18) of the energy beam (7) deviating from a circular shape on the work area (11) relative to the vector alignment of the specify at least one radiation vector (21).

2. Planning device (15) according to claim 1, wherein the planning device (15) is set up to calculate a beam shape (18) of the energy beam (7) and/or an energy input parameter of the Energy beam (7), in particular a beam power and / or a displacement speed to specify.

3. Planning device (15) according to one of the preceding claims, wherein the planning device (15) is set up to determine a vector orientation for at least one radiation vector (21) of the plurality of radiation vectors (21), and for the at least one radiation vector ( 21) specifying a beam orientation for the beam shape (18) assigned to the at least one radiation vector (21).

4. planning device (15) according to any one of the preceding claims, wherein the planning device (15) is set up to at least two radiation vectors (21) of the plurality of radiation vectors (21) each have a different beam shape (18) and / or assign a different energy input parameter depending on at least one vector parameter, wherein the at least one vector parameter is preferably selected from a group consisting of: a location of the irradiation vector (21) on the work area (11), an assignment of the irradiation vector (21) to a certain vector group, and a vector length of the irradiation vector (21).

5. Planning device (15) according to one of the preceding claims, wherein the planning device (15) is set up to define a plurality of irradiation areas (23) on the work area (11) and to assign the irradiation vectors (21) to the irradiation areas (23), wherein the planning device (15) is set up to specify a beam shape (18) of the energy beam (7) for each irradiation area (23) of the plurality of irradiation areas (23), and to divide the irradiation areas (23) depending on a vector length of the irradiation vectors (21) set in the irradiation areas (23).

6. Planning device (15) according to one of the preceding claims, wherein the planning device (15) is set up to calculate at least one contour distance (a, b) of the at least one radiation vector (21 ) to a contour line (22) of a component contour (24) of a component layer to be produced on the powder material layer in the working area (11) as a function of at least one distance parameter, wherein the at least one distance parameter is selected from a group consisting of : The beam shape (18) assigned to the at least one radiation vector (21), and a contour angle which the at least one radiation vector (21) encloses with the contour line (22).

7. Planning device (15) according to one of the preceding claims, wherein the planning device (15) is set up to determine the vector orientation and the specification of the beam orientation for each component layer of a plurality of successively generated in the work area (11). to carry out component layers.

8. planning device (15) according to any one of the preceding claims, wherein the planning device (15) is set up to a number of displacements of the energy beam (7) along a contour line (22) of a component contour (24) on the powder material layer in the work area ( 11) component layer to be produced depending on at least one to specify contour travel parameters, with the at least one contour travel parameter being selected from a group consisting of: the beam shape (18) assigned to at least one radiation vector (21) adjoining the contour line (22), and a contour angle which the at least includes an irradiation vector (21) adjacent to the contour line (22) with the contour line (22).

9. Planning device (15) according to one of the preceding claims, wherein the planning device (15) is set up to assign a specific beam shape (18) to each energy beam (7) of a plurality of energy beams (7) and to the irradiation vectors (21) respectively to assign an energy beam (7) of the plurality of energy beams (7) with a matching beam shape (18).

10. Manufacturing facility for the additive manufacturing of components (3) from a powder material, with

- A beam generating device (5) which is set up to generate an energy beam (7), a scanner device (9) which is set up to irradiate a work area (11) locally selectively with the energy beam (7) in order to use the energy beam ( 7) to produce a component (3) from the powder material arranged in the work area (11),

- An optical device (17) which is set up to shape and align the energy beam (7), and with

- A control device (13) which is operatively connected to the scanner device (9) and set up to control the scanner device (9), wherein

- the control device (13) is also operatively connected to the optical device (17) in order to control the controllable optical device (17), and wherein

- the control device (13) has a planning device (15) according to one of claims 1 to 9 or is designed as a planning device (15) according to one of claims 1 to 9.

11. A method for planning a locally selective irradiation of a work area (11) with an energy beam (7) in order to use the energy beam (7) to produce a component (3) from a powder material arranged in the work area (11), wherein for at least one Irradiation vector (21) of a plurality of irradiation vectors (21) for irradiating a layer of powder material arranged in the work area (11) with the energy beam (7), a vector alignment in a coordinate system on the work area (11) being determined, and wherein for the at least one radiation vector (21) a beam alignment for a beam shape (18) of the energy beam (7) deviating from a circular shape on the work area (11) relative to the vector alignment of the at least one radiation vector (21) is specified.

12. Computer program product, comprising machine-readable instructions, on the basis of which a method according to claim 11 is carried out on a computing device when the computer program product is executed on the computing device.

13. A method for additively manufacturing a component (3) from a powder material by means of a manufacturing device (1) according to claim 10, wherein a work area (11) is locally selectively irradiated with the energy beam (7) in order to remove the component by means of the energy beam (7). (3) from the powder material arranged in the working area (11), with a layer of powder material arranged in the working area (11) being exposed to the energy beam (7) in the form of a plurality of irradiation vectors (21), with a beam shape deviating from a circular shape (18) the energy beam (7) on the work area (11) for at least one irradiation vector (21) of the plurality of irradiation vectors (21) relative to a vector orientation of the at least one irradiation vector (21) in a coordinate system on the work area (11) is aligned.

14. The method according to claim 13, wherein a different beam shape (18) and/or a different energy input parameter depending on at least one vector parameter is used for at least two irradiation vectors (21) of the plurality of irradiation vectors (21), the at least one vector - parameter is preferably selected from a group consisting of: a location of the irradiation vector (21) on the work area (11), an assignment of the irradiation vector (21) to a specific vector group, and a vector length of the irradiation vector (21).

15. The method according to claim 13 or 14, wherein the energy beam (7) is repeatedly displaced along a contour line (22) of a component contour (24) of a component layer to be produced on the powder material layer in the working area (11), with a number of displacements of the energy beam (7) along the contour line (22) is selected as a function of at least one contour travel parameter, the at least one contour travel parameter being selected from a group consisting of: the at least one radiation vector ( 21) associated beam shape (18), and a contour angle which the at least one of the contour line (22) adjoining radiation vector (21) includes with the contour line (22).