Method and device for controlling an irradiation system for producing workpieces

Patent metadata

Field	Value
Publication number	US-11639028-B2
Application number	US-201816487290-A
Country	US
Kind code	B2
Filing date	Jan 15, 2018
Priority date	Feb 22, 2017
Publication date	May 2, 2023
Grant date	May 2, 2023

Abstract

The invention relates to a method for controlling an irradiation system (20), the irradiation system (20) being used in a device (10) for the additive manufacturing of three-dimensional workpieces and comprising at least three irradiation units (22a-d, 50), the method comprising the following steps: a) defining an irradiation region (30a-d) for each of the irradiation units (22a-d, 50), the irradiation regions (30a-d) each comprising a portion of an irradiation plane (28) which extends parallel to a carrier (16) of the device (10), and the irradiation regions (30a-d) being defined such that they overlap in a common overlap region (34); b) irradiating a raw material powder layer on the carrier (16) to produce a workpiece layer; c) arranging a further raw material powder layer on the already jetted raw material powder layer to produce a further workpiece layer. d) The invention also relates to a device for performing this method.

First claim

The invention claimed is:

1. A method for controlling an irradiation system, wherein the irradiation system is used in a device for the additive manufacture of three-dimensional workpieces, the irradiation system comprising at least three irradiation units, wherein the method comprises the following steps:
defining an irradiation region for each of the irradiation units, wherein the irradiation regions each comprise a portion of an irradiation plane which extends parallel to a carrier of the device and wherein the irradiation regions each comprise at least a portion of a raw material powder layer arranged on the carrier to produce a workpiece layer, and wherein the irradiation regions are so defined that they overlap in a common overlap region;
subdividing the overlap region into a plurality of partitioning regions, each of which is associated with at least one of the irradiation units, wherein partitioning region boundaries of the partitioning regions intersect at a common intersection point;
irradiating the raw material powder layer arranged on the carrier using the defined irradiation regions to produce a workpiece laver;
arranging a further raw material powder layer on the already irradiated raw material powder layer to produce a further workpiece layer; and
changing the partitioning region boundaries so that the partitioning regions differ from one another between two successive raw material powder layers, wherein a position of the common intersection point is varied.

2. The method as claimed in claim 1 , wherein the proportions of the irradiation regions relative to a total area of the irradiation plane are each greater than 0% and less than 100%, and/or
wherein the proportion of the overlap region relative to a total area of the irradiation plane is greater than 0% and less than 100%.

3. The method as claimed in claim 1 , wherein the irradiation units and/or centers of the irradiation regions span a polygon.

4. The method as claimed in claim 1 , further comprising the step of:
selecting at least one irradiation unit to be used for irradiation of the overlap region.

5. The method as claimed in claim 4 , wherein the selection step is carried out again before the further workpiece layer is irradiated.

6. The method as claimed in claim 4 , wherein the selection of the at least one irradiation unit to be used for the overlap region differs between two successive raw material powder layers.

7. The method as claimed in claim 4 , wherein a plurality of irradiation units is selected for the irradiation of the overlap region, in order to irradiate the overlap region by the plurality of irradiation units in parallel or in succession.

8. The method as claimed in claim 4 , wherein, for selecting the at least one irradiation unit for the overlap region, the following step is carried out:
selecting at least one irradiation unit for the irradiation of the overlap region in the irradiation regions of which the workpiece layer to be produced also extends outside the overlap region; or
selecting at least one irradiation unit for the irradiation of the overlap region in the irradiation regions of which the workpiece layer to be produced does not extend outside the overlap region.

9. The method as claimed in claim 1 , wherein the defining of the irradiation regions is carried out in such a manner that the arrangement of the overlap region within the irradiation plane changes between two successive raw material powder layers.

10. The method as claimed in claim 1 , wherein the variation of the intersection point takes place randomly or according to a predetermined pattern.

11. The method as claimed in claim 1 , wherein the irradiation system comprises at least one group of at least three irradiation units, comprising the steps of:
arranging the irradiation units in such a manner that the irradiation units together span a polygon; and
defining the irradiation region for each irradiation unit in such a manner that the common overlap region is arranged at least in part within the polygon.

12. The method of claim 1 , wherein the plurality of partitioning regions fill the entirety of the overlap region.

13. The method of claim 1 , wherein subdividing the overlap region comprises dividing the overlap region into the plurality of partitioning regions such that a union of the plurality of partitioning regions equals the overlap region.

14. The method of claim 1 , wherein changing the partitioning region boundaries comprises changing the partitioning region boundaries so that each of the plurality of partitioning regions differs in size between two successive raw material powder layers.

15. A device for the layer by layer manufacture of three-dimensional workpieces, comprising:
an irradiation system having at least three irradiation units;
a carrier which is adapted to receive a raw material powder layer which is irradiatable by the irradiation system to produce a workpiece layer;
a control unit which is adapted to define an irradiation region for each of the irradiation units, wherein the irradiation regions each comprise a portion of an irradiation plane which extends parallel to the carrier, and wherein the control unit is further adapted to define the irradiation regions in such a manner that they overlap in a common overlap region;

wherein the control unit is further adapted to control the device in such a manner that the overlap region is subdivided into a plurality of partitioning regions, each of which is associated with at least one of the irradiation units, wherein partitioning region boundaries of the partitioning regions intersect at a common intersection point, and the partitioning region boundaries are changed so that the partitioning regions differ from one another between two successive raw material powder layers, wherein a position of the common intersection point is varied; and
wherein the control unit is further adapted to control the device in such a manner that raw material powder layers arranged in succession on the carrier are irradiatable using the defined irradiation regions to produce successive workpiece layers.

16. The device of claim 15 , wherein the plurality of partitioning regions fill the entirety of the overlap region.

17. The device of claim 15 , wherein subdividing the overlap region comprises dividing the overlap region into the plurality of partitioning regions such that a union of the plurality of partitioning regions equals the overlap region.

18. The device of claim 15 , wherein changing the partitioning region boundaries comprises changing the partitioning region boundaries so that each of the plurality of partitioning regions differs in size between two successive raw material powder layers.

Assignees

• SLM Solutions Group AG

Inventors

• Wiesner Andreas
• Wilkes Jan
• Thiel Christiane
• Roesgen Lukas

Classifications

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y30/00 Primary

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B22F10/366

  Scanning parameters, e.g. hatch distance or scanning strategy · CPC title