Methods for the additive manufacture of components in layers, and corresponding computer program products

Patent metadata

Field	Value
Publication number	US-11986995-B2
Application number	US-201916407389-A
Country	US
Kind code	B2
Filing date	May 9, 2019
Priority date	Nov 14, 2016
Publication date	May 21, 2024
Grant date	May 21, 2024

Abstract

The disclosure provides methods of additive manufacture of components in layers in a powder bed by at least two laser beams that can be deflected two-dimensionally over the same powder bed region. Each laser focal spot is projected onto the power bed and is or is set to a diameter of less than or equal to 300 μm. Components to be produced in the powder bed region are manufactured by each of the laser beams, and each individual surface contour of the component is manufactured solely by one of the laser beams.

First claim

What is claimed is:

1. A method for the additive manufacture of a component to be produced in layers in a powder bed, the method comprising:
directing at least two laser beams by at least two respective laser scanners to a region of the powder bed to impinge from above onto a top surface of the powder bed, wherein the at least two laser beams are each deflected two-dimensionally over the powder bed region and wherein a laser spot of each laser beam is projected onto the powder bed below the corresponding scanner, and the at least two laser spots on the top surface of the powder each have the same or almost the same spot diameter of less than or equal to 300 μm so that all of the at least two laser beams are equally suitable to produce the component with a same surface roughness; and
manufacturing the component in the powder bed with the at least two laser beams, wherein a surface contour of the component can be manufactured by either one of the at least two laser beams with the same surface roughness, wherein all surface contours of an outer surface of the component are manufactured solely by a first of the at least two laser beams, and wherein an internal region of the component is manufactured by a second of the at least two laser beams.

2. The method of claim 1 , wherein the laser spot diameter of each one of the at least two laser beams is less than or equal to 200 μm.

3. The method of claim 1 , wherein the laser spot diameter of each one of the at least two laser beams is less than or equal to 100 μm.

4. The method of claim 1 , wherein at least one surface contour, which extends over multiple layers and is oriented parallel or almost parallel to the powder bed, is manufactured with the same laser beam as a surface contour oriented perpendicular or almost perpendicular to the powder bed.

5. The method of claim 1 , wherein at least one surface contour, which extends over multiple layers and is oriented parallel or almost parallel to the powder bed, is manufactured with the same laser beam as a surface contour not oriented parallel or almost parallel to the powder bed.

6. The method of claim 1 , wherein all the surface contours of an outer surface, an inner surface, or both an inner surface and an outer surface of the component are manufactured solely by one of the laser beams.

7. The method of claim 1 , wherein all the surface contours of the component are manufactured solely by one of the laser beams.

8. The method of claim 1 , wherein all the surface contours extending over multiple layers and oriented perpendicular or almost perpendicular to the powder bed, and all other surface contours not oriented parallel or almost parallel to the powder bed are manufactured solely by one of the laser beams.

9. The method of claim 1 , wherein multiple components to be manufactured in the powder bed region are each manufactured simultaneously by different laser beams.

10. The method of claim 1 , wherein the powder bed region that can be scanned by each of the laser beams includes at least about ⅔ of the powder bed.

11. The method of claim 1 , wherein the powder bed region that can be scanned by each of the laser beams includes the entire powder bed.

12. The method of claim 1 , wherein the manufacture of the surface contour is simultaneous with the manufacture of the internal region of the component.

13. A computer program product that has code adapted to perform steps for a method for the additive manufacture of a component to be produced in layers in a powder bed when the program is run on a machine control system of a machine, the method comprising:
directing at least two laser beams by two respective laser scanners to a powder bed to impinge from above onto the powder bed directly below the corresponding scanner, wherein the at least two laser beams are deflected two-dimensionally over the powder bed and wherein laser spots of the at least two laser beams projected onto a top surface of the power bed each have the same or almost the same spot diameter of less than or equal to 300 μm so that all of the at least two laser beams are equally suitable to produce the component with a same surface roughness; and
manufacturing the component in the powder bed with the at least two laser beams, wherein a surface contour of the component can be manufactured by either one of the at least two laser beams with the same surface roughness, wherein all surface contours of an outer surface of the component are manufactured solely by a first of the at least two laser beams, and wherein an internal region of the component is manufactured by a second of the at least two laser beams.

14. A method for the additive manufacture of a component to be produced in layers in a powder bed, the method comprising:
directing at least two laser beams by two respective laser scanners to a powder bed to impinge from above onto a top surface of the powder bed directly below the corresponding scanner, wherein the at least two laser beams are each deflected two-dimensionally over the powder bed and wherein laser spots of the at least two laser beams projected onto the top surface of the powder bed each have the same or almost the same spot diameter of less than or equal to 200 μm so that all of the at least two laser beams are equally suitable to produce the component with a same surface roughness; and
manufacturing the component in the powder bed with the at least two laser beams, wherein a surface contour of the component can be manufactured by either one of the laser beams with the same surface roughness, wherein all surface contours of the outer and inner surfaces of the component are manufactured solely by a first of the at least two laser beams, and wherein an internal region of the component is manufactured by a second of the at least two laser beams.

15. A method for the additive manufacture of multiple components to be produced in layers in a powder bed, the method comprising:
directing at least two laser beams by at least two respective laser scanners to a region of the powder bed to impinge from above onto a top surface of the powder bed, wherein the at least two laser beams are each deflected two-dimensionally over the powder bed region and wherein a laser spot of each laser beam is projected onto the top surface of the powder bed below the corresponding scanner, and the at least two laser spots each have the same or almost the same spot diameter of less than or equal to 300 μm so that all of the at least two laser beams are equally suitable to produce the components with a same surface roughness; and
manufacturing the multiple components in the powder bed simultaneously by the at least two laser beams, wherein a surface contour of the components can be manufactured by either one of the laser beams with the same surface roughness, wherein all surface contours of an outer surface of at least one of the components are manufactured solely by a first of the at least two laser beams, and wherein an internal region of the at least one of the components is manufactured by a second of the at least two laser beams.

Assignees

• Trumpf Laser & Systemtechnik Gmbh

Inventors

• Huber Uwe
• Bauer Johannes
• Thielmann Michael
• Wagner Joachim
• Ortmann Jürgen
• Allenberg-Rabe Matthias
• Breitling Detlef
• Buchbinder Damien
• Krist Florian

Classifications

• B29C64/153 Primary

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F10/36

  of energy beam parameters · CPC title

• B22F10/366

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

• B22F12/45

  Two or more · CPC title