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WO2025209821A1 - Procédé utilisé pour surveiller une couche de matériau en poudre formée par un dispositif de production, et dispositif de production - Google Patents

Procédé utilisé pour surveiller une couche de matériau en poudre formée par un dispositif de production, et dispositif de production

Info

Publication number
WO2025209821A1
WO2025209821A1 PCT/EP2025/057218 EP2025057218W WO2025209821A1 WO 2025209821 A1 WO2025209821 A1 WO 2025209821A1 EP 2025057218 W EP2025057218 W EP 2025057218W WO 2025209821 A1 WO2025209821 A1 WO 2025209821A1
Authority
WO
WIPO (PCT)
Prior art keywords
powder material
detection devices
material layer
images
area detection
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2025/057218
Other languages
German (de)
English (en)
Inventor
Valentin BLICKLE
Alexander Stahl
Julia Peters
Marc GRONLE
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.)
Trumpf Laser und Systemtechnik Se
Original Assignee
Trumpf Laser und Systemtechnik Se
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 Trumpf Laser und Systemtechnik Se filed Critical Trumpf Laser und Systemtechnik Se
Publication of WO2025209821A1 publication Critical patent/WO2025209821A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/31—Calibration of process steps or apparatus settings, e.g. before or during manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/37—Process control of powder bed aspects, e.g. density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • 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
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T7/00—Image analysis
    • G06T7/30—Determination of transform parameters for the alignment of images, i.e. image registration
    • G06T7/33—Determination of transform parameters for the alignment of images, i.e. image registration using feature-based methods
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2207/00—Indexing scheme for image analysis or image enhancement
    • G06T2207/30—Subject of image; Context of image processing
    • G06T2207/30108—Industrial image inspection
    • G06T2207/30144—Printing quality
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2207/00—Indexing scheme for image analysis or image enhancement
    • G06T2207/30—Subject of image; Context of image processing
    • G06T2207/30204—Marker
    • 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 method for monitoring a powder material layer of a manufacturing device, wherein the manufacturing device is set up to produce at least one component layer by layer from a plurality of powder material layers of a powder material arranged in a layer sequence sequentially in a working area of the manufacturing device by locally selective solidification of the powder material arranged in the working area by means of energy beams, as well as a manufacturing device.
  • a powdered material such as a metal or ceramic powder
  • a powdered material is irradiated with electromagnetic radiation.
  • Thin powder layers are successively applied in a chamber on a build platform to form three-dimensional objects by irradiating the respective powder layers with an irradiation beam, such as a laser beam.
  • Corresponding devices are referred to as additive manufacturing devices, 3D printing systems, selective laser sintering machines, or selective laser melting machines, and the like. For the functioning of such a device, see, for example, EP 2 732 890 A2.
  • Powder bed fusion (PBF) additive manufacturing in which thin layers of powder, e.g., metal, ceramic, or thermoplastic powder, are gradually applied and locally solidified with one or more jets to successively build up the component, is particularly suitable for the production of complex and delicate components.
  • Machines suitable for performing PBF processes are referred to below as PBF machines are referred to as powder bed fusion (PBF) machines.
  • Lasers and electron beam systems are typically used as beam sources. When a laser source is used, the process is also referred to as powder bed fusion - laser-based (PBF-LB).
  • the beam can sinter or melt the powder to solidify it, thereby bonding it to previously solidified component layers.
  • sintering is referred to as selective laser sintering or electron beam sintering
  • melting is referred to as selective laser melting or electron beam melting
  • Powder bed-based additive manufacturing of metal powder using a laser beam for example, is also known as laser metal fusion.
  • a manufacturing device used in this process typically has at least one scanner device configured to shift the energy beams.
  • a first energy beam By using multiple energy beams, it is possible for a first energy beam to produce a first component in a work area of the manufacturing device, while at the same time a second energy beam produces a second component in the work area.
  • the quality of the powder material layer to be machined in the powder bed, as well as the quality of the molten components, are crucial factors for producing high-quality components.
  • the quality of the powder material layer to be machined also affects the tools used in the production equipment. Likewise, poor tool quality leads to an inadequate powder material layer.
  • DE 10 2018 218 991 A1 proposes taking optical images of the working layer of the powder bed during the production of a component and examining these images for defects in the working layer, such as insufficient powder dosage or smoke particles.
  • defects that can be corrected such as an incomplete working layer
  • the production system can be controlled in such a way that the working layer or powder material layer is completed before the powder is melted by the exposure source.
  • the system is shut down to prevent damage to the tools, especially the Powder coating tools should be avoided.
  • the latter measure leads to undesirable delays in the production process, especially in the series production of components.
  • the present disclosure is directed, at least in part, to improving or overcoming one or more aspects of prior systems, and in particular to reducing or completely eliminating downtime in the process.
  • the present disclosure is directed, at least in part, to improving upon or entirely overcoming one or more aspects of prior systems.
  • the object is achieved in particular by a method for monitoring a powder material layer of a manufacturing device, wherein the manufacturing device is designed to produce at least one component layer by layer from a plurality of Layer sequence of powder material layers of a powder material arranged sequentially in a work area of the production device by locally selective solidification of the powder material arranged in the work area by means of energy beams, wherein the method comprises the following steps: applying a powder material layer in the work area by moving an application device, taking a plurality of images of different partial areas of the powder material layer by means of a plurality of work area detection devices, and processing the images of the powder material layer taken by the plurality of work area detection devices.
  • a composite image of the working area consisting of the different sub-areas of the powder material layer is generated from the images recorded by the plurality of working area detection devices.
  • the work area detection devices consist of cameras or line scan cameras.
  • the working area detection devices are aligned such that the images of the partial regions of the powder material layer recorded by the plurality of working area detection devices at least partially overlap.
  • the images of the partial areas of the powder material layer captured by the multiple work area detection devices are first intrinsically calibrated and their distortion corrected, whereby the checkerboard method of Zhang is preferably used for the intrinsic calibration.
  • the images of the partial regions of the powder material layer recorded by the plurality of work area detection devices are extrinsically calibrated in a further step such that the images are perspectively corrected, subsequently aligned with one another and combined into one image in a final step.
  • At least one marking is arranged in a common overlap region of the partial regions of the powder material layer, which marking is configured to align the images of the partial regions of the powder material layer recorded by the plurality of working area detection devices with one another.
  • the at least one marking in the common overlap region of the partial regions of the powder material layer is used in such a way that the images of the partial regions of the powder material layer recorded by the plurality of working area detection devices are combined to form one image.
  • the at least one marking contains a bore, milling, structure in the working area, structure in the powder material layer or binary coding, wherein the marking is preferably a barcode, QR code or ArUco marker.
  • a brightness adjustment and/or a contrast correction can be carried out at the transition areas of two images, and preferably the brightness of the images is adjusted.
  • At least one marking is arranged in a common overlap region of the partial regions of the powder material layer, wherein a drift compensation of the working area detection devices is carried out by means of the at least one marking, preferably comprising the following steps: a) determining the positioning of the at least one marking by means of an image processing algorithm, b) determining the homography transformation between the working area detection devices by means of the determined positions of the at least one marking, and c) recalculating the extrinsic calibration parameters of the working area detection devices.
  • the object is also achieved by providing a manufacturing device for producing at least one component layer by layer from a plurality of powder material layers of a powder material arranged sequentially in a layer sequence in a work area of the manufacturing device, by locally selective solidification of the powder material arranged in the work area.
  • the manufacturing device comprises at least one beam generation device configured to generate at least one energy beam, at least one scanner unit configured to displace the at least one energy beam in the work area, an application device for applying a powder material layer to the work area, a plurality of work area detection devices configured to detect the work area, and a control unit configured to carry out the method for monitoring a powder material layer of a manufacturing device.
  • the working area detection devices are aligned such that the images of the partial areas of the powder material layer recorded by the plurality of working area detection devices at least partially overlap.
  • the images of the partial regions of the powder material layer recorded by the plurality of work area detection devices have at least one marking in a common overlap region.
  • the powder material can be exposed using energy beams while the application device is located within the work area. This avoids further downtime and thus accelerates the process, which in turn leads to more cost-effective component production.
  • the images can be taken synchronized with the movement of the application device.
  • images can be taken of both the powder material layer already exposed by the energy beams and the powder material layer above it that is still to be exposed, and a composite image of both a powder material layer already exposed by the energy beams and a powder material layer that is still to be exposed can be generated.
  • the energy beams can solidify the powder material both before and after the application device.
  • this allows both the current powder material layer, which has not yet been completely applied, and the previous powder material layer to be exposed to the energy beams.
  • Fig. 2 is a schematic representation of an embodiment of a working area of a manufacturing device for producing at least one component
  • Fig. 3 shows an embodiment of a method for providing a composite image of two partial areas of the work area.
  • the production facility 1 further comprises a substrate plate 13, which is arranged beneath the scanner units 9a, 9b, 9c and onto which a build material 15, such as a powder or a powder bed, is applied layer by layer.
  • a build material 15 such as a powder or a powder bed
  • the substrate plate 13 is adjusted by a desired distance in the Z direction, i.e., in the direction of increasing distance from the scanner units 9a, 9b, 9c, and then a new layer of powder material or powder bed is applied using an application device 17, such as a coating module or a powder slider.
  • a layer of powder material is applied.
  • Scrapers, blades, or rollers, for example, can also be considered as application devices 17.
  • the build chamber 3 is gas-tight and includes a gas inlet 21 and a gas outlet 23. Usually, there are one or more secondary inlets to support a laminar primary flow and prevent splashes and smoke from spreading to undesired locations (not shown).
  • the build chamber 3 can be filled with an inert gas, e.g., nitrogen or argon, via the gas inlet 21 to prevent oxidation of the powder material 15. Together with the gas outlet 23, a uniform protective gas flow can also be formed over the powder material 15 to remove condensates, powder particles, and other particles that are ejected into the atmosphere during solidification with energy beams, thus reducing potential interference with the beam 11a, 11b, 11c.
  • the gas outlet 23 can also be used to evacuate the build chamber 3 so that electron beams can be used as energy beams 11a, 11b, 11c. For this purpose, the build chamber 3 must be made vacuum-tight.
  • the control unit 5 can also have a data interface, via which, for example, control programs can be imported. When executing a control program via a control interface, the control unit 5 can perform all steps necessary for layer-by-layer additive manufacturing on the device, such as activating or deactivating energy beams 11a, 11b, 11c, deflecting them with the scanner units 9a, 9b, 9c, adjusting the substrate plate 13 along the Z-axis, or triggering a powder material application using the application device 17.
  • the manufacturing device 1 also comprises two work area detection devices 12, such as cameras, which are configured to capture images of the powder material layer.
  • the work area detection devices 12 are Embodiment mounted on the ceiling of the installation space 3, preferably directly above the working level 18.
  • Figure 2 shows a schematic representation of an embodiment of a work area or a work plane 18 of a manufacturing device 1 for producing the at least one component 19.
  • Figure 2 shows the work plane 18 or the work area in a plan view.
  • the work plane 18 contains, on the one hand, the powder material 15 and/or, on the other hand, the underlying, at least one manufactured or to-be-manufactured component 19.
  • markers 25 are applied outside the work area 18.
  • the markers 25 serve as a reference for the work area detection devices 12, according to which the images generated by the work area detection devices 12 can be aligned with each other.
  • Figure 2 shows two so-called field of view regions 30, which indicate which regions can be detected by a respective work area detection device 12.
  • a first work area detection device 12 can detect the left field of view region 30, and a second work area detection device 12 can detect the right field of view region 30.
  • the two field of view areas 30 have a common overlap area 32, i.e., in this overlap area 32, multiple work area detection devices 12 can detect the same area or work area 18.
  • the markings 25 are arranged in this common overlap area 32 of the work area detection devices 12, which allow the images captured by the work area detection devices 12 to be aligned with one another.
  • FIG. 3 shows an embodiment of a method for providing a composite image of two partial areas of the work area 18.
  • each of the two work area detection devices 12 records an image of the two partial areas of the work area 18.
  • each work area detection device 12 records an image of its respective field of view 30. This leads to a left output image and a right output image.
  • the intrinsic calibration of the two output images takes place.
  • the intrinsic calibration takes place in this The implementation example uses the so-called checkerboard method by Zhang (https://www.researchgate.net/publication/303233579 Zhang's Camera Calibration Algorithm In-Depth tutorial and Implementation; "Zhang's Camera Calibration Algorithm: In-Depth Tutorial and Implementation", May 2016, DOE10.13140/RG.2.1.1166.1688/1, Report number: HGB16-05). Furthermore, the distortion of the two images is corrected. In a third step, the processed images are extrinsically calibrated in such a way that the images are perspectively corrected and subsequently aligned. In a fourth and final step, the images are combined into a single image.
  • Substrate plate 15 Powder material or building material

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Automation & Control Theory (AREA)
  • Mechanical Engineering (AREA)
  • Theoretical Computer Science (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Vision & Pattern Recognition (AREA)
  • Analytical Chemistry (AREA)
  • Plasma & Fusion (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention concerne un procédé utilisé pour surveiller une couche de matériau en poudre formée par un dispositif de production (1), le dispositif de production (1) étant conçu pour produire au moins un composant (19) couche par couche en utilisant une pluralité de couches de matériau en poudre constituées d'un matériau en poudre (15), les couches étant arrangées selon une séquence chronologique successive dans une région de travail (18) du dispositif de production (1) par solidification locale sélective du matériau en poudre (15) disposé dans la région de travail (18), en faisant appel à des faisceaux d'énergie (11a, 11b, 11c), le procédé comprenant les étapes consistant à : appliquer une couche de matériau en poudre dans la région de travail par déplacement d'un dispositif d'application (17), capturer une pluralité d'images de différentes sous-régions de la couche de matériau en poudre au moyen d'une pluralité de dispositifs de détection de région de travail (12), et traiter les images de la couche de matériau en poudre capturées par la pluralité de dispositifs de détection de région de travail (12).
PCT/EP2025/057218 2024-04-03 2025-03-17 Procédé utilisé pour surveiller une couche de matériau en poudre formée par un dispositif de production, et dispositif de production Pending WO2025209821A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102024109299.8A DE102024109299A1 (de) 2024-04-03 2024-04-03 Verfahren zum Überwachen einer Pulvermaterialschicht einer Fertigungsvorrichtung, sowie eine Fertigungsvorrichtung
DE102024109299.8 2024-04-03

Publications (1)

Publication Number Publication Date
WO2025209821A1 true WO2025209821A1 (fr) 2025-10-09

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Country Status (2)

Country Link
DE (1) DE102024109299A1 (fr)
WO (1) WO2025209821A1 (fr)

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