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WO2018172079A1 - Optimisation de chevauchement - Google Patents

Optimisation de chevauchement Download PDF

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Publication number
WO2018172079A1
WO2018172079A1 PCT/EP2018/055616 EP2018055616W WO2018172079A1 WO 2018172079 A1 WO2018172079 A1 WO 2018172079A1 EP 2018055616 W EP2018055616 W EP 2018055616W WO 2018172079 A1 WO2018172079 A1 WO 2018172079A1
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WO
WIPO (PCT)
Prior art keywords
layer
section
boundary region
computer
shape
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2018/055616
Other languages
German (de)
English (en)
Inventor
Martin Schade
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EOS GmbH
Original Assignee
EOS GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by EOS GmbH filed Critical EOS GmbH
Publication of WO2018172079A1 publication Critical patent/WO2018172079A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/4097—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by using design data to control NC machines, e.g. CAD/CAM
    • G05B19/4099—Surface or curve machining, making 3D objects, e.g. desktop manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for 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
    • 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
    • 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
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • 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
    • B22F12/38—Housings, e.g. machine housings
    • 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
    • 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
    • B22F2301/00—Metallic composition of the powder or its coating
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/49—Nc machine tool, till multiple
    • G05B2219/49008—Making 3-D object with model in computer memory
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to a computer-assisted method for generating a control data record for a generative layer building apparatus and to a device suitable for carrying out the method.
  • Generative layer construction devices and related methods are generally characterized by fabricating objects in them by solidifying a shapeless building material layer by layer.
  • the solidification may, for example, be brought about by supplying heat energy to the building material by irradiating it with electromagnetic radiation or particle radiation (eg laser sintering (SLS) or laser melting or electron beam melting) or by inducing a crosslinking reaction in the building material (eg stereolithography ).
  • electromagnetic radiation or particle radiation eg laser sintering (SLS) or laser melting or electron beam melting
  • SLS laser sintering
  • crosslinking reaction in the building material eg stereolithography
  • WO 2016/110440 A1 describes a corresponding device in which different laser beams are assigned to different areas of a layer, wherein there are areas in which a plurality of beams can act on the building material, ie areas to which not only one laser beam but several laser beams are directed can be.
  • FIG. 11 illustrates this procedure on the basis of a construction field on which four laser beams can act simultaneously.
  • those regions in which only one of the four laser beams can be used during solidification are designated AI to A4.
  • Areas in which two laser beams can be used together for solidification are indicated by the letter "B", with the numbers following the letters denoting which of the four laser beams (numbered 1 to 4) are used.
  • WO 2016/110440 A1 deals with the problem that it is necessary to coordinate which of the laser beams that can be used in a common area is directed to a specific location in this area.
  • the coordination can in particular be such that a laser beam, in the subregion only a few places within a
  • Layer to be solidified can be used in an adjacent subregion in which many points must be solidified.
  • the inventors have found that in the boundary region of the action zones of different laser beams, for example in the region B12 in FIG. 11, at the boundary line G between the region B121, which is solidified by the laser beam 1, and the region B122, that from the laser beam 2 is solidified, the Aufschmelz or solidification behavior of the building material is slightly different than in other areas.
  • the inventors were able to determine that slight inhomogeneities occur at the boundary line, which lead to mechanical weak points, especially when accumulated over a larger volume can.
  • the use of several lasers can significantly reduce the production time, it may be necessary to accept losses in the quality of the manufactured objects.
  • an object of the present invention to provide a method and an apparatus by means of which objects can be produced in a short time with high quality by means of a generative layer construction method, in particular an additive manufacturing method.
  • the object is achieved by a computer-aided method according to claim 1, a generative layer construction method according to claim 13, a device for computer-aided generation of a control data set according to claim 14 and a computer program according to claim 15.
  • Further developments of the invention are claimed in the dependent claims inventive method be further developed by below or in the dependent claims executed features of the devices according to the invention and vice versa.
  • the features described in connection with a device can also be used to develop another device according to the invention, even if this is not explicitly stated.
  • a computer-assisted method according to the invention for generating a control data record for a generative layer building apparatus for producing a three-dimensional object by means of the same, the production comprising the steps:
  • the insertion means is adapted to direct a plurality of beams to different regions of an applied layer, each of the beams, where it strikes the layer, acting on the building material, in particular so as to solidify it, indicates:
  • a second step in a layer data set a plurality of adjoining partial cross sections, ie to be solidified subregions of an object cross section are determined, is determined for each of the partial cross sections, with which beam to consolidate the bodies in this partial cross section,
  • partial cross-sections are determined such that a boundary region, ie an area lying at the boundary between different partial cross-sections, in its shape and / or position in the layer plane with respect to the shape and / or position of a boundary region in one of the immediately preceding or immediately following Layer assigned shift data set is different and
  • the layer data record modified in the second step is provided as a control data record for the generative layer building apparatus.
  • the radiation source may be, for example, a laser or an electron beam source, but it would also be conceivable for a device for 3D printing which generates a binder beam or a UV light source in stereolithography.
  • beam is intended to express that not only rays are meant that have a round cross section when hitting the building material, but also rays that z. B. have a linear cross-section or even radiation, which is registered at the same time in a larger area of the building material (ie area).
  • a data record which contains a data model of a build-up material layer to be consolidated at the locations of an object cross-section during the production process is regarded as a shift data record.
  • such a data model has a two-dimensional representation of the object cross-section to be consolidated in one layer by means of one or more beams.
  • different locations in an object cross-section are usually solidified by different beam bundles.
  • a certain point of the object cross-section is solidified by directing multiple beams to this point.
  • the layer data set can, but need not, even more information regarding the production of the object cross section may be included, for. B. the layer thickness, the diameter of an incident on the building material beam, etc.
  • the two shift records do not necessarily have to be read together (ie simultaneously). It is also possible that there is a greater time interval between the access operations on the two shift records, for example, one of the two shift records was read in at an earlier time.
  • the decomposition into partial cross sections takes place in such a way that all points within a partial cross section are to be solidified with the same bundle of rays.
  • the mechanical parameters eg the elongation at break
  • a bead on the object surface as through Limits between the areas of action, which may occur in several layers, can be avoided.
  • the boundary between the action areas is referred to as the "boundary area".
  • border between two areas is a borderline.
  • the term "boundary area" was chosen.
  • any real line can be considered an area.
  • the method is preferably carried out in such a way that the boundary regions in at least two successive layers do not completely cover one another, that is to say not 100%, and even more preferably cover each other at 0%, ie not at all.
  • the percentages of overlap refer to overlapping a percentage of the area of one of the boundary areas with the other.
  • the overlapping areas need not match in shape and / or size even with complete coverage. For example, suppose that in a layer, a boundary region has a linear shape, in particular the shape of a straight line
  • Line so should in the overlying layer also has a linear boundary area of the same shape and line orientation, both border areas by at least 50%, preferably by 100%, more preferably by 120% of the line width in a direction perpendicular to the line shape against each other be postponed.
  • the method is carried out such that the shape and / or position of the boundary region in the layer plane are set so that they repeat at the earliest after n layers in the manufacturing process, where n is a natural number greater than one.
  • n is a natural number greater than one.
  • the shape and / or position of the boundary region in the layer plane are set so that they repeat in the manufacturing process at the latest after m layers, where m is a natural number greater than or equal to n.
  • the definition of the shape or position of a boundary region can be simplified, since these do not have to be different in all layers.
  • the shape and / or position of the boundary region in the layer plane can be set so that they change during the manufacturing process in the construction direction according to a first periodic function, in particular a sine function, triangular function or rectangular function.
  • a first periodic function in particular a sine function, triangular function or rectangular function.
  • the location of the boundary region in the layer planes would be described by a sinusoidal function at a section through the layer stack at a suitable location or (at discrete Locations) can at least approximate.
  • the mechanical strength of a manufactured object can be particularly high.
  • the reason is that (for example in the case of a triangular function), a toothing of the partial cross sections solidified with different beam bundles occurs in different layers.
  • the shape and / or position of the boundary region in the layer plane can be set so that they additionally change in the construction direction in the construction direction according to a second periodic function, which is superimposed on the first periodic function and preferably has a shorter period than the first periodic function , whereby In spite of the gearing effect just described, care can be taken to avoid excessive accumulation of boundary regions (in particular with regard to beads on the object surface).
  • this is also applied to boundary regions which lie in the contour of an object cross section and delimit therefrom two sections of the contour region which are solidified by different solidification beam bundles.
  • the sections of the contour area are also considered as partial cross-sections of an object cross section, which is permissible, since normally the contour area is run over with a beam of finite diameter for solidification and thus can be regarded as a two-dimensional area.
  • the shape and / or position of the boundary region in the layer plane can be set such that in at least one layer the position of the boundary region is twisted relative to another rotation axis perpendicular to the layer planes, preferably by an angle is greater than or equal to 5 °, more preferably an angle greater than or equal to 10 °, even more preferably an angle greater than or equal to 20 °, provided that the shape of the boundary region in the two layers is substantially equal.
  • the position and / or shape of a boundary region can be varied in a particularly effective and simple manner, since (complete) overlapping is avoided in a particularly effective manner by rotations.
  • the rotation according to the already mentioned second periodic function can take place over a plurality of layers.
  • the shape and / or position of the boundary region in the layer plane can be set such that they change in the layers in the direction of construction according to a random function.
  • the shape and / or position of the boundary region in the layer plane can also be set so that they change according to a function resulting from a superimposition of the first and / or second periodic function with a random function.
  • overlay with a random function it is meant that the values of the first or second periodic functions are changed randomly, similarly to e.g. B. a sine function, which is not an exact sine function, but is "noisy".
  • a random function it is also possible to use a function which does not lead to a randomly determined position and / or shape of border regions, but to the fact that the position and / or shape of boundary regions repeat in a pattern that is the case Viewing is not readily apparent.
  • Such a procedure is particularly suitable in connection with boundary areas present on the surface (or in the contour) of objects.
  • the change in the shape and / or position of the boundary region from layer to layer can take place depending on whether a boundary region is located in a pre-determined section of an object to be produced.
  • This can be used, for example, to meet different requirements for different sections of an object to be produced.
  • the position and / or shape of a border region can be varied more from layer to layer than in a section remote from the surface, in order to meet the high demands on the optical quality of the surface. to meet.
  • the method can be carried out only for one or more predetermined subsections of an object to be produced.
  • the production of the object can additionally be optimized with regard to production time and quality via the number of beams used for solidifying.
  • a generative layer construction method for producing a three-dimensional object by means of a generative layer construction apparatus, the production comprising the steps:
  • the insertion means is adapted to direct a plurality of beams simultaneously to different regions of the applied layer, each of the beams acting on the building material where it impinges on the layer, in particular so that it is solidified,
  • a generative layer construction device has a control device which controls a production process of an object using a control data record generated by a method according to the invention.
  • a device for computer-aided generation of a control data set for a generative layer building apparatus for producing a three-dimensional object by means of the same, the production comprising the steps:
  • the insertion means is adapted to direct a plurality of beams simultaneously to different regions of the applied layer, each of the beams acting on the building material where it impinges on the layer, in particular so that it is solidified,
  • an access unit which is suitable for accessing at least two layer data sets which have data models of a corresponding number of build material layers to be selectively solidified during production and characterized in a data model by means of which beam the build material adjoins the respective object cross section to solidify appropriate bodies
  • a fixing unit which is suitable for defining in a layer data set a plurality of adjoining partial cross sections, that is to be solidified subregions of an object cross section, it being determined for each of the partial cross sections with which beam the points in this partial cross section are to be solidified,
  • partial cross-sections are set so that a boundary region, that is, an area lying at the boundary between different partial cross-sections, in its shape and / or position in the layer plane is different from the shape and / or position of a boundary region in a layer data record assigned to the immediately preceding or the immediately following layer, and
  • a provisioning unit which is suitable for providing the shift data record modified by the setting unit as a control data record for the generative layer building apparatus.
  • the device according to the invention is suitable for carrying out any of the variants of the method according to the invention for generating a control data record.
  • the mentioned access unit can be an input interface which can read data from a mobile data carrier or receives data via a network or else reads out data directly from a memory.
  • the device according to the invention can not only be implemented as a separate unit, but can also be part of a more comprehensive EDP system (for example, a CAD design system) or integrated into a generative layer construction device. In the latter two cases, the access unit is then preferably a software interface that communicates with other system components.
  • the device according to the invention does not necessarily have to be part of a generative layer construction device.
  • the access unit can also access layer data records which are stored in a memory present in the device according to the invention.
  • a computer program according to the invention comprises program code means for carrying out all steps of a method according to the invention for generating a control data set or a generative layer construction method according to the invention, when the computer program is executed on a data processor, in particular a data processor cooperating with a generative layer construction device.
  • "Interaction" means that the data processor is either integrated into the generative layer construction device or can exchange data with it.
  • the implementation of the method according to the invention for generating a control data record and the associated device by means of software allows easy installation on different EDP systems at different locations (for example, the creator of the design of the object to be processed or the operator of the generative layer building apparatus).
  • FIG. 1 shows a schematic, partially sectional view of an exemplary apparatus for generatively producing a three-dimensional object according to an embodiment of the invention
  • FIG. 2 and 3 each show a schematic plan view of a partial region of the construction field of a generative layer construction device for explaining the procedure according to the invention
  • FIG. 2 shows a schematic representation of a method according to the invention for generating a control data set for a generative layer construction device
  • 5 shows the schematic structure of an apparatus for generating a control data record according to the present invention
  • FIG. 6 shows a schematic plan view of a partial region of the construction field of a generative layer construction device for explaining the procedure according to the invention
  • FIG. 11 shows a schematic plan view of a construction field of a generative layer construction device for explaining the procedure in the presence of a plurality of solidification beams.
  • a generative layer construction device according to the invention will first be described below, using the example of a laser sintering melting device, with reference to FIG. 1. It should be noted at this point that in the present application, the term “number” always in the sense of "one or more” to understand. It should also be noted that not only one object but also several objects can be produced simultaneously by means of a generative layer construction device according to the invention, even in cases in which only one object is mentioned.
  • the laser sintering or laser melting device 1 For constructing an object 2, the laser sintering or laser melting device 1 contains a process chamber or construction chamber 3 with a chamber wall 4. In the process chamber 3, an upwardly open building container 5 is arranged with a container wall 6. A working plane 7 is defined by the upper opening of the construction container 5, wherein the area of the working plane 7 which lies within the opening and which can be used to construct the object 2 is referred to as construction field 8.
  • a movable in a vertical direction V carrier 10 is arranged, on which a base plate 11 is mounted, which closes the container 5 down and thus forms its bottom.
  • the base plate 11 may be a plate formed separately from the carrier 10, which is fixed to the carrier 10, or it may be integrally formed with the carrier 10.
  • a building platform 12 can still be mounted on the base plate 11 as a construction base on which the object 2 is built up.
  • the object 2 can also be built on the base plate 11 itself, which then serves as a construction document.
  • FIG. 1 the object 2 to be formed in the container 5 on the building platform 12 is shown below the working plane 7 in an intermediate state with a plurality of solidified layers surrounded by building material 13 which has remained unconsolidated.
  • the laser sintering or melting apparatus 1 further comprises a reservoir 14 for a building material 15, in this example an electromagnetic radiation solidifiable powder, and a coater 16 movable in a horizontal direction H for applying the building material 15 within the construction field 8 the process chamber 3, a radiant heater 17 may be arranged, which serves for heating the applied building material 15.
  • a radiant heater 17 for example, an infrared radiator can be provided.
  • the exemplary laser sintering device 1 further includes an exposure device 20 with a laser 21 which generates a laser beam 22 which is deflected by a deflection device 23 and by a focusing device 24 via a coupling window 25 which is mounted on the top of the process chamber 3 in the chamber wall 4 , is focused on the working level 7.
  • the laser sintering device 1 includes a control device 29, via which the individual components of the device 1 are controlled in a coordinated manner for carrying out the building process.
  • the control device may also be mounted partially or completely outside the device.
  • the controller may include a CPU whose operation is controlled by a computer program (software).
  • the computer program can be stored separately from the device on a storage medium, from which it can be loaded into the device, in particular into the control device.
  • the carrier 10 is lowered layer by layer by the control device 29, the coater 16 is driven to apply a new powder layer and the deflection device 23 and optionally also the laser 21 and / or the focusing device 24 driven to solidify the respective layer to the respective Object corresponding locations by means of the laser by scanning these locations with the laser.
  • an exposure apparatus may include one or more gas or solid state lasers, or any other type of laser, such as a laser.
  • Laser diodes in particular Vertical Cavity Surface Emitting Laser (VCSEL) or Vertical External Cavity Surface Emitting Laser (VECSEL), or a row of these lasers.
  • VCSEL Vertical Cavity Surface Emitting Laser
  • VECSEL Vertical External Cavity Surface Emitting Laser
  • any device can be used with which energy can be selectively applied to a layer of the building material as electromagnetic radiation or particle radiation.
  • a laser for example, another light source, an electron beam or any other energy or radiation source can be used, which is suitable to solidify the building material.
  • the specific structure of a laser sintering or melting device shown in FIG. 1 is therefore only an example and can of course also be modified, in particular when using a different exposure device than the one shown.
  • a laser sintering or laser melting device has been described as an example of a generative layer construction device in FIG. 1, the invention is not based on laser sintering or laser melting restricted. It may also be used in conjunction with other methods of generatively producing a three-dimensional object by layering and selectively strengthening a building material.
  • laser melting, FLM application of a thermoplastic material from a die
  • 3D printing, mask sintering and stereolithographic processes are mentioned.
  • the exposure device 20 is replaced by another insertion device depending on the method, in the case of a 3D printing process by a device which injects one or more binder beams onto the building material a stereolithography process by a UV light source.
  • the entry device contains any type of radiation source from which at least one beam impinging on the construction material is directed.
  • the present invention idea can be realized most advantageously in connection with a generative layer construction device in which an insertion device is set up so that it can direct a plurality of beams onto a region of a building material layer.
  • various materials may be used, preferably powders or pastes or gels, in particular metal powder, but also plastic powder, ceramic powder or sand, whereby the use of filled or mixed powders is possible.
  • powders or pastes or gels in particular metal powder, but also plastic powder, ceramic powder or sand, whereby the use of filled or mixed powders is possible.
  • plastic powder, ceramic powder or sand Especially in stereolithography (liquid) photopolymers are used.
  • a production process proceeds in such a way that the control unit 29 processes a control instruction set which is a statement of how to place layers of the construction material one after the other. and selectively irradiate portions of the respective layers corresponding to the cross section of an object to be manufactured with the laser radiation to solidify the building material.
  • the control instruction set thus contains information about the points to be consolidated within a layer and the type of decomposition of the object to be produced into layers.
  • control command set is based on a computer-based model of the object (s) to be produced, preferably a CAD solid model.
  • production-specific information also flows into the control instruction set, for example the position and orientation of the objects in the container 5 or a beam diameter when a laser beam strikes the building material.
  • control instruction set also contains the layer information, i. how the object (s) to be produced are subdivided into layers that correspond to the building material layers during the layered generative production.
  • the control instruction set defines, in particular, the thickness of the layer application and the locations at which solidification of the building material is to be effected by irradiation for each building material layer during production.
  • the control instruction set can thus be regarded as a totality of all control data predetermined for the control of the production process in a generative layer construction device.
  • the control data related to a single layer are also referred to as a layer data set.
  • the control instruction set also contains all for controlling the
  • Exposure device required data, whereby u.a. the energy density of the radiation emitted by the exposure device and, if appropriate, the travel speed of the jet can be defined via the construction field 8.
  • the procedure according to the invention is described below by way of example with reference to FIGS. 2 to 5.
  • an apparatus 100 for generating a control data record for a specific generative layer building apparatus includes an access unit 101, a determination unit 102 and a provision unit 103 Apparatus 100 for generating a control data record will be described with reference to FIG. Figures 2 and 3 serve to further illustrate.
  • Fig. 2 shows a plan view of a partial area of the construction field 8 of a generative layer building apparatus in which the working areas of two solidifying beams or beam bundles, i. the locations in the construction field, to which the two solidification jets or, respectively, beam bundles can be directed, are shown.
  • AI and A2 denote those regions in which only the first or second hardening beam, eg, the second or the second solidification jet, is formed.
  • a laser beam can get used in the solidification.
  • the area within which both solidification jets can be used together for solidification is marked B12.
  • FIG. 2 shows, by way of example, a parallelogram-shaped object cross-section 55 of an object to be produced, which is to be solidified during the production process in a layer k of the building material.
  • Fig. 2 shows as seen a plan view of the layer k of the building material.
  • a boundary region 35 separates both partial cross sections from one another.
  • the border area 35 is a borderline.
  • any real line can be considered an area.
  • a device 100 according to the invention for generating a control data set for a generative layer building apparatus shown in FIG. 5 in order to carry out the computer-assisted method according to the invention in a first step, an access unit is used.
  • unit 101 is accessed at least two shift records of the object to be manufactured. In the process sequence shown in FIG. 4, this is step S1.
  • the term access means that the access unit reads out a shift data record from a memory or else accepts the data corresponding to the shift data record via a network.
  • the two shift records do not necessarily have to be read together (ie simultaneously). It is also possible that there is a greater time interval between the access operations on the two shift records, for example, one of the two shift records was read in at an earlier time.
  • the access unit can also access a memory in the device 100 in which the layer data sets are present.
  • a layer data set only has to contain information for the associated building material layer at which points of the building material layer during the production of the object a solidification of the building material is to be effected by directing beam bundles onto the building material layer.
  • process information eg layer thickness or beam diameter, etc.
  • it may already be specified in the layer data record by means of which beam the building material is to be solidified at one point. If the latter information is not yet present in the layer data set, then the device 100 according to the invention determines with which beam the material to be consolidated is to be solidified at one point of the building material layer.
  • the definition unit 102 modifies a layer data record in such a way that an object cross-section is divided into a plurality of adjoining partial cross-sections, wherein the decomposition is such that all locations within a partial cross-section are to be solidified with the same beam. Furthermore, the fixing unit 102 determines the partial cross-sections in such a way that the position and / or shape of the boundary regions (in FIG. 2 by way of example only a boundary region 35 is shown) in directly superimposed layers are different from each other. This becomes clear from a comparison of FIGS. 2 and 3:
  • FIG. 3 shows a plan view of the same subregion of the construction field as FIG. 2.
  • FIG. 3 shows an object cross-section 65 of an object to be produced which is to be solidified in the layer k + 1 of the building material, which during the manufacturing process is directly adjacent to the layer k of FIG 2 follows.
  • two different beam bundles associated partial cross sections 41 and 42 which are separated by a boundary region 45.
  • the boundary regions 35 and 45 lie at different locations within the construction field and, in particular, do not overlap at any point. This is because, on the one hand, the position (location) of the border areas within the construction field is different and, on the other hand, the shape of the border areas is different: Even if both had the same position, complete coverage would not be possible.
  • the delivery unit 103 provides the shift data record of a generative layer building apparatus modified as a control data record in step S2.
  • a control data record can be regarded as a subset of a control command set of a generative layer building apparatus.
  • a control record provided by the provisioning unit 103 may also be integrated by the provisioning unit 103 itself into a control instruction set.
  • provisioning also includes forwarding the control data record to a data processing device which integrates the control data record into a control command record, or a direct forwarding to a generative layering device.
  • modified layer data sets according to the invention need not be provided individually for a generative layer construction process. Rather, several Modified shift records first collected and then be provided in their entirety as a control record.
  • n 2
  • n 3
  • a prime number is chosen as the value for n.
  • Fig. 7 shows a schematic section through a layer stack in the manufacture of an object.
  • the horizontal lines shown here are each intended to represent a layer in the data model that corresponds to a building material layer during the production of the object. Layer thicknesses are neglected in the scheme (as well as in Fig. 8). For the sake of simplicity, it is further assumed that in the section of FIG.
  • Layer stack the object cross-sections each occupy the entire width of the section and are divided into partial cross-sections 701 and 702, respectively. Reference numerals are assigned for convenience only to the top three layers in FIG. 7). One recognizes in the cut in each layer a border area 705 (the reference number is again only for two layers shown), which assumes the same position again after five layers. Although the boundary areas do not overlap in directly superimposed layers at any point, the boundary areas in the layer plane (ie horizontally in FIG. 7) are distributed over only an area of limited extent. Depending on the application, it may be appropriate to limit the extent of the area within the construction field, eg. B. to a width of 500 ⁇ or 200 ⁇ or 100 ⁇ . It is also possible to specify minimum values for the shift of the position of the boundary region from layer to layer, for. B. 5 ⁇ , 20 ⁇ or even 50 ⁇ . 9 shows how the mutual distance d of two boundary regions in superimposed layers can be determined.
  • the horizontal layers of the boundary region in the layers can be described by means of a periodic function as a function of the layer number (assuming that higher layer numbers are assigned later in the manufacturing process to layers to be consolidated than earlier in the production process to be consolidated layers).
  • a periodic function as a function of the layer number (assuming that higher layer numbers are assigned later in the manufacturing process to layers to be consolidated than earlier in the production process to be consolidated layers).
  • FIG. 8 shows a similar example with partial cross-sections 801 and 802 and boundary regions 805, which assume the same position within the layer plane in every other layer. Again, the locations can be approximated by a sawtooth function.
  • Fig. 8 illustrates how by the periodic change in the position of the boundary regions, a toothing of partial cross sections takes place by z.
  • a partial cross section 802 where it adjoins the boundary region 805, is flanked in the layers immediately above and below partial cross sections 801,
  • FIG. 6 shows an alternative shape of the boundary region compared to FIGS. 2 and 3. It can be seen in Fig. 6, the absence of "corners" in the shape of the boundary region.
  • the shape of the boundary region in FIGS. 2 and 3 takes account of the fact that regions to be solidified in a layer are usually scanned strip-wise with a beam. That is, within a rectangular or square area (a stripe), the hardening beam travels in parallel tracks over the building material. The angular course of the respective boundary region in FIGS.
  • FIGS. 2 and 3 results from the fact that the partial cross-sections have been selected such that strips bordering on the boundary region adjoin one another in the respective partial cross-sections. It can be seen in FIGS. 2 and 3 that the boundary region in FIG. 2 has been modified in its position and shape such that straight sections of the linear shape of the boundary region have been displaced in parallel in the layer plane. In the case of a variation of the position of the boundary regions, it is likewise possible to obtain the position of a boundary region in a subsequent layer by twisting the position of the boundary region in the underlying layer about an axis of rotation perpendicular to the layers.
  • FIG. 10 illustrates a variant of the procedure according to the invention in which this method is also applied to boundary regions which lie in the contour of an object cross section and delimit therefrom two sections of the contour region which are solidified by different hardening beam bundles.
  • an object cross-section 95 can be seen, whose contour region (edge) has two sections 91 and 92 which are solidified by means of different hardening beams or hardening beam bundles.
  • a contour region is solidified in such a way that the hardening beam used, which has a certain diameter where it encounters the building material, moves away from the contour. Therefore, it is permissible to designate sections of the contour of an object cross section as two-dimensional areas. The same applies to the point at which two sections of the contour area adjoin one another. As in the interior of an object cross-section, where two partial cross-sections adjoin one another, it is also true in the contour region that two sections will generally not exactly adjoin one another but there will be a slight gap or slight overlap at the boundary. Therefore, the two boundary points 9192 and 9291 in Figure 10 are referred to as boundary regions.
  • boundary area 9192 is thus that from which the partial cross section (contour section) 92 is solidified
  • boundary area 9291 is that from which the partial cross section (contour section) 91 is solidified.
  • the position of the boundary region is varied according to the invention from layer to layer in the same way as has been described above for boundary regions lying in the interior of an object cross-section.
  • a change in the position of a boundary region in the contour is particularly useful for surface areas that are optically perceptible or have to be designed as uniformly as possible.
  • inaccessible surface areas on the other hand, Soon beads or dents on the surface of the object can be tolerated. Accordingly, it makes sense to proceed according to the invention differently in different sections of the object to be produced.
  • the position and / or shape of the boundary regions in different subsections of the object can not only be varied differently, but rather the procedure according to the invention can generally be limited to only one or more subsections of the object determined in advance.
  • a device 100 according to the invention for generating a control data set of a generative layer construction device can be realized not only by software components but also solely by hardware components or mixtures of hardware and software.
  • interfaces mentioned in the present application do not necessarily have to be designed as hardware components, but can also be implemented as software modules, for example if the data fed in or output via them can be taken over by other components already implemented on the same device or must be passed to another component only by software.
  • the interfaces could consist of hardware and software components, such as a standard hardware interface specifically configured by software for the specific application.
  • several interfaces can also be combined in a common interface, for example an input-output interface.

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Abstract

L'invention concerne un procédé informatique de génération d'un ensemble de données de commande pour un dispositif de construction de couches générateur, selon lequel une unité d'inscription (20) est constituée dans ce dernier afin de diriger une pluralité de faisceaux de rayons (22) sur différentes zones d'une couche exposée. Selon une première étape (S1), on accède à au moins deux ensembles de données de couche qui comportent des modèles de données d'un nombre correspondant de couches de matériaux de construction à agréger sélectivement pendant la fabrication. Selon une deuxième étape (S2), plusieurs sections transversales partielles (31, 32, 41, 42) adjacentes les unes aux autres sont déterminées dans un ensemble de données de couche. Les sections transversales partielles (31, 32, 41, 42) sont déterminées de telle sorte qu'une zone limite (35, 45) est différente dans sa forme et/ou dans sa position dans le plan de couche par rapport à la forme et/ou la position d'une zone limite (35, 45) dans un ensemble de données de couche associé à la couche directement précédente ou directement suivante. Selon une troisième étape (S3), l'ensemble de données de couche modifié lors de la deuxième étape (S2) est préparé en tant qu'ensemble de données de commande pour le dispositif de construction de couches générateur.
PCT/EP2018/055616 2017-03-24 2018-03-07 Optimisation de chevauchement Ceased WO2018172079A1 (fr)

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