Patent Application
20190054687
The invention relates to an apparatus for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of a powdered build material which can be consolidated by means of an energy beam.
Respective apparatuses for additively manufacturing three-dimensional objects, e.g. technical components, are widely known and may be embodied as selective laser sintering apparatuses, selective laser melting apparatuses or selective electron beam melting apparatuses, for instance.
It is known that the structural, i.e. particularly mechanical, properties of additively manufactured three-dimensional objects are significantly influenced by the cooling behavior of the respective selectively consolidated portions of layers of powdered build material which have been selectively irradiated by the energy beam during the additive manufacturing process. The significant influence of the cooling behavior of the selectively consolidated portions of the layers of powdered build material on the structural properties of the additively manufactured three-dimensional objects is based on the fact that the cooling behavior essentially determines the microstructure of the additively manufactured three-dimensional objects. As an example, the cooling behavior may influence the build-up of internal stresses forming the basis of (micro)-crack formation within additively manufactured three-dimensional objects which may compromise the structural properties of the additively built three-dimensional objects.
In view of the above, it is the object of the present invention provide an apparatus for additively manufacturing three-dimensional objects allowing for a reliable and, in particular highly integrateable, determination of the cooling behavior of layers of powdered build material which have been selectively irradiated by an energy beam during an additive manufacturing process.
This object is achieved by an apparatus for additively manufacturing three-dimensional objects according to claim 1. The claims depending on claim 1 relate to possible embodiments of the apparatus according to claim 1.
The apparatus described herein is an apparatus for additively manufacturing three-dimensional objects, e.g. technical components, by means of successive layerwise selective irradiation and consolidation of layers of a powdered build material (“build material”) which can be consolidated by means of an energy beam. A respective build material can comprise at least one of a metal powder, a ceramic powder, or a polymer powder. A respective energy beam can be a laser beam or an electronic beam. A respective apparatus can be a selective laser sintering apparatus, a selective laser melting apparatus, or a selective electron beam melting apparatus, for instance.
The apparatus comprises a number of functional devices which are operable during its operation. Each functional device may comprise a number of functional units. Exemplary functional devices are a build material application device, e.g. a coating device, configured to apply a layer of build material which is to be selectively irradiated and consolidated, e.g. in a build plane of a process chamber of the apparatus, and an irradiation device configured to selectively irradiate and consolidate portions of a layer of build material with at least one energy beam.
The apparatus described herein comprises an irradiation device configured to generate at least a first and a second energy beam, whereby the second energy beam follows the path/track of the first energy beam with a defined local and/or time offset. The irradiation device is thus, configured to selectively irradiate a layer of build material with at least a first and a second energy beam. Thereby, the irradiation device is configured to control the motion of the first and second energy beam in such a manner that the second energy beam (directly) follows the path/track of the first energy beam with a defined local and/or time offset.
The irradiation device may be configured to generate the first energy beam with different beam properties, particularly a higher beam power, smaller beam size, etc., compared with the second energy beam.
The first energy beam may have a beam power high enough to fuse, i.e. particularly melt, build material while being selectively irradiated with the first energy beam. The energy input into selectively irradiated portions of a layer of build material by the first energy beam is thus, sufficient to fuse, particularly melt, selectively irradiated portions of a layer of build material. Hence, the first energy beam serves for fusing of build material.
The second energy beam may have a beam power not high enough to fuse, i.e. particularly melt, build material while being selectively irradiated with the second energy beam. The energy input into selectively irradiated portions of a layer of build material by the second energy beam is thus, not sufficient to selectively fuse, particularly melt, selectively irradiated portions of a layer of build material. The energy input into selectively irradiated portions of a layer of build material by the second energy beam is yet, sufficient for tempering portions of a layer of build material after being selectively irradiated with the first energy beam. Hence, the second energy beam serves for tempering of selectively irradiated portions of a layer of build material. Tempering allows for controlling the temperature and thus, the cooling behavior of portions of a layer of build material after being selectively irradiated with the first energy beam.
As will be apparent from the below description of possible embodiments of the apparatus, the irradiation device may comprise a number of functional units, e.g. at least one beam generating unit configured to generate at least one energy beam, i.e. particularly at least a first and a second energy beam, and at least one beam deflection unit (scanning unit) configured to deflect an energy beam to different positions of a layer of build material.
The apparatus further comprises a detection device configured to detect (electromagnetic) radiation emitted or reflected from the or a portion of a layer of build material which was selectively irradiated by the first energy beam. The detection device may comprise a at least one detection element configured to detect (electromagnetic) radiation emitted or reflected from the or a portion of a layer of build material which was selectively irradiated by the first energy beam. The detection device may be a sensor device, e.g. an optical or thermographical sensor device, e.g. an optical or thermographical camera, photodiode, etc., the detector element may be sensor element, e.g. an optical or thermographical sensor element, e.g. an optical or thermographical camera element, photodiode element, etc.
The apparatus further comprises an evaluation device configured to evaluate detected radiation emitted from a portion of a layer of build material which was selectively irradiated by the first energy beam with regard to the cooling behavior of the respective portion of the layer of build material which was selectively irradiated by the first energy beam. The evaluation is based on the insight that radiation emitted from a portion of a layer of build material which was selectively irradiated by the first energy beam is a direct or indirect measure for the temperature and thus, cooling behavior of the respective portion of the layer of build material which was selectively irradiated by the first energy beam. The evaluation device may comprise at least one evaluation algorithm configured to evaluate detected radiation emitted from a portion of a layer of build material which was selectively irradiated by the first energy beam with regard to the cooling behavior of the respective portion of the layer of build material which was selectively irradiated by the first energy beam. The evaluation device may be embodied in hard- and/or software.
By means of detecting radiation emitted or reflected from the or a portion of a layer of build material which was selectively irradiated by the first energy beam and evaluating detected radiation emitted from a portion of a layer of build material which was selectively irradiated by the first energy beam with regard to the cooling behavior of the respective portion of the layer of build material which was selectively irradiated by the first energy beam, an apparatus for additively manufacturing three-dimensional objects allowing for a reliable and, in particular highly integrateable, determination of the cooling behavior of respective selectively consolidated portions of layers of build material which have been selectively irradiated by an energy beam during an additive manufacturing process is provided.
It was mentioned that the irradiation device may comprise a number of functional units allowing for generating at least a first and a second energy beam. According to an embodiment, the irradiation device may comprise a first beam generation unit configured to generate the first energy beam and a second beam generation unit configured to generate the second energy beam. According to another embodiment, the irradiation device may comprise only one beam generating unit configured to generate an energy beam (which is split so as to generate the first and second energy beam) and an associated beam splitting unit configured to split the energy beam generated by the beam generating unit so as to generate the first and second energy beam. The irradiation device may also comprise at least one beam deflection unit configured to deflect an energy beam to different positions of a layer of build material. The beam deflection unit may comprise a number of, particularly moveably supported, beam deflection elements, e.g. deflection mirrors. It is possible that the irradiation device comprises at least a first and a second beam deflection unit, whereby a first beam deflection unit is assigned to the first energy beam so as to deflect the first energy beam to different positions of a layer of build material and a second beam deflection unit is assigned to the second energy beam so as to deflect the second energy beam to different positions of a layer of build material.
In either case, the irradiation device may comprise at least one beam guidance unit configured to guide the first and/or second energy beam along an optical path. The beam guidance unit may comprise a number of optical elements, e.g. fibers, lenses, mirrors, etc. building the optical path. The beam guidance unit is typically, disposed between the beam generating unit and a beam deflection unit so as to guide an energy beam along an optical path extending from a respective beam generating unit to a respective beam deflection unit.
In particular, the irradiation device may comprise a beam guidance unit configured to guide at least the second energy beam, particularly between a beam generation unit configured to generate the second energy beam and a beam deflection unit configured to deflect at least the second energy beam to different positions of a layer of build material.
The detection device may be assigned to the beam guidance unit configured to guide at least the second energy beam. In particular, the detection device may be arranged in an on-axis arrangement with respect to the beam deflection unit configured to deflect at least the second energy beam. A respective on-axis arrangement of the detection device allows both in constructive and functional regard for a highly integrated arrangement of the detection device. A respective on-axis arrangement of the detection device further allows for obtaining high-dynamic and high-resolution detection information, e.g. high-dynamic and high-resolution detection images, of the detected portions of respective layers of build material. A respective on-axis arrangement of the detection device also allows for obtaining coordinate values, etc. of respective detected information.
The beam guidance unit may comprise at least one optical element, e.g. a semi-reflective mirror element, configured to guide radiation emitted from a portion of a layer of build material which was selectively irradiated by the first energy beam to the detecting device. Hence, the same optical path can be used for an energy beam and for the radiation emitted from a portion of a layer of build material which was selectively irradiated by the first energy beam. The direction of extension of the radiation emitted from a portion of a layer of build material which was selectively irradiated by the first energy beam through the optical path built by the respective beam guidance unit is at least partly a reverse direction of extension of the energy beam through the optical path.
The evaluation device may be configured to generate an evaluation information describing/indicating the cooling behavior of the portion of the layer of build material which was selectively irradiated by the first energy beam evaluated from the detected radiation emitted from a portion of a layer of build material which was selectively irradiated by the first energy beam. The evaluation information may describe/indicate diverse chemical and/or physical parameters being directly or indirectly related to the cooling behavior of the portion of the layer of build material which was selectively irradiated by the first energy beam. Examples of respective parameters are composition of atmosphere, radiation power, temperature, etc. The evaluation information can be communicated to diverse functional devices of the apparatus by means of communication links between these functional devices. The evaluation information can be communicated to a user interface device, e.g. a screen, of the apparatus and hence, output to a user.
The apparatus comprises a control device assigned to diverse functional devices of the apparatus and configured to control operation of diverse functional devices of the apparatus. As an example, the control device may be configured to control operation of the irradiation device. In particular, the control device may be configured to control operation of the irradiation device on basis of an evaluation information determined by the evaluation device. Hence, by controlling operation of the irradiation device on basis of a respective evaluation information, the first and/or second energy beam may be controlled in such a manner so as to achieve a desired cooling behavior of portions of layers of build material which were selectively irradiated by the first energy beam and therefore, a desired microstructure within the object to be additively built. Controlling operation of the irradiation device and thus, of the cooling behavior may be implemented as a control-loop allowing for a real-time control of the cooling behavior and other factors influencing the quality of the additively manufactured object.
The detection device may be configured to additionally detect radiation emitted from a portion of a layer of build material which is currently selectively irradiated by the first energy beam. In such a manner, not only the cooling behavior of portions of layers of build material which were selectively irradiated by the first energy beam, but also the fusing behavior of portions of layers of build material which are currently selectively irradiated by the first energy beam can be detected. Of course, the apparatus may also comprise at least one further detection device configured to detect radiation emitted from a portion of a layer of build material which is currently selectively irradiated by the first energy beam.
In either case, the or a further evaluation device may be configured to evaluate detected radiation emitted from a portion of a layer of build material which is currently selectively irradiated by the first energy beam with regard to the fusing behavior of the portion of the layer of build material which is currently selectively irradiated by the first energy beam. The (further) evaluation device may comprise at least one evaluation algorithm configured to evaluate detected radiation emitted from a portion of a layer of build material which is currently selectively irradiated by the first energy beam with regard to the fusing behavior of the portion of the layer of build material which is currently selectively irradiated by the first energy beam. The evaluation device may be embodied in hard- and/or software.
The invention also relates to an evaluation device for an apparatus as specified above. The evaluation device being configured to at least evaluate detected radiation emitted from a portion of a layer of build material which was selectively irradiated by a first energy beam generated by an irradiation device of the apparatus with regard to the cooling behavior of the portion of the layer of build material which was selectively irradiated by the first energy beam. The annotations concerning the apparatus apply to the evaluation device in analogous manner.
Further, the invention also relates to a method for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers of a build material which can be consolidated by means of an energy beam. The method comprises the steps of generating at least two energy beams, whereby a second energy beam follows the path of a first energy beam with a defined local and/or time offset; detecting radiation emitted from a portion of a layer of build material which was selectively irradiated by the first energy beam; and evaluating detected radiation emitted from a portion of a layer of build material which was selectively irradiated by the first energy beam with regard to the cooling behavior of the portion of the layer of build material which was selectively irradiated by the first energy beam. The method may be implemented as a selective laser sintering method, a selective laser melting method or a selective electron beam melting method, for instance. The annotations concerning the apparatus apply to the method in analogous manner.
Exemplary embodiments of the invention are described with reference to the Fig., whereby the sole Fig. shows a principle drawing of a section of an apparatus for additively manufacturing three-dimensional objects according to an exemplary embodiment.
The sole Fig. shows a principle drawing of a section of an apparatus 1 for additively manufacturing three-dimensional objects, e.g. technical components, by means of successive layerwise selective irradiation and accompanying consolidation of layers 2 of a powdered build material 3, e.g. a metal powder, which can be consolidated by means of an energy beam 4, e.g. a laser beam. The apparatus 1 can be a selective laser melting apparatus, for instance.
The apparatus 1 comprises a number of functional devices which are operable during its operation. Each functional device may comprise a number of functional units. The apparatus 1 comprises a control device 23 assigned to the functional devices of the apparatus 1 and configured to control operation of the functional devices.
Exemplary functional devices are a build material application device 5, e.g. a coating device, configured to apply a layer 2 of build material 3 which is to be selectively irradiated and consolidated in a build plane E of a process chamber 7 of the apparatus 1, and an irradiation device 8 configured to selectively irradiate and consolidate portions of a layer 2 of build material 2 with at least one energy beam 4.
The irradiation device 8 is configured to generate at least a first energy beam 4 and a second energy beam 9, whereby the second energy beam 9 follows the path/track of the first energy beam 4 with a defined offset Δ. The irradiation device 8 is thus, configured to selectively irradiate a layer 2 of build material 3 with at least a first and a second energy beam 4, 9. Thereby, the irradiation device 8 is configured to control the motion of the first and second energy beam 4, 9 in such a manner that the second energy beam 9 (directly) follows the path/track (indicated by arrow 10) of the first energy beam 4 with the defined local offset Δ.
The irradiation device 8 is configured to generate the first energy beam 4 with different beam properties compared with the second energy beam 9. The first energy beam 4 has a beam power high enough to fuse, i.e. particularly melt, build material 3 while being selectively irradiated with the first energy beam 4. The energy input into selectively irradiated portions of a respective layer 2 of build material 3 by the first energy beam 4 is thus, sufficient to fuse, particularly melt, build material 3. Hence, the first energy beam 4 serves for fusing of build material 3.
The second energy beam 9 has a beam power not high enough to fuse, i.e. particularly melt, build material 3 while being selectively irradiated with the second energy beam 9. The energy input into selectively irradiated portions of a respective layer 2 of build material 3 by the second energy 9 beam is thus, not sufficient to selectively fuse, particularly melt, build material 3. The energy input into selectively irradiated portions of a respective layer 2 of build material 3 by the second energy beam 9 is yet, sufficient for tempering portions of a layer 2 of build material 3 after being selectively irradiated with the first energy beam 4. Hence, the second energy beam 9 serves for tempering of build material 3. Tempering allows for controlling the temperature and thus, the cooling behavior of portions of a respective layer 2 of build material 3 after being selectively irradiated with the first energy beam 4.
The apparatus 1 further comprises a detection device 11 configured to detect (electromagnetic) radiation 12 emitted or reflected from a portion of a layer 2 of build material 3 which was selectively irradiated by the first energy beam 4. The detection device 11 comprises a at least one detection element 13 configured to detect (electromagnetic) radiation emitted or reflected from the portion of the layer 2 of build material 3 which was selectively irradiated by the first energy beam 4. The detection device 11 may be a sensor device, e.g. an optical or thermographical sensor device, e.g. an optical or thermographical camera, photodiode, etc., the detector element 13 may be sensor element, e.g. an optical or thermographical sensor element, e.g. an optical or thermographical camera element, photodiode element, etc.
The apparatus 1 further comprises an evaluation device 14 configured to evaluate detected radiation 12 with regard to the cooling behavior of the respective portion of the layer 2 of build material 3 which was selectively irradiated by the first energy beam 4. The evaluation is based on the insight that radiation 12 emitted from the portion of the layer 2 of build material 3 which was selectively irradiated by the first energy beam 4 is a measure for the temperature and thus, cooling behavior of the respective portion of the layer 2 of build material 3 which was selectively irradiated by the first energy beam 4. The evaluation device 14 may comprise at least one evaluation algorithm configured to evaluate detected radiation 12.
The evaluation device 14 is configured to generate an evaluation information describing/indicating the cooling behavior of the portion of a layer 2 of build material 3 which was selectively irradiated by the first energy beam 4 evaluated from the detected radiation 12 emitted from the portion of the layer 2 of build material 3 which was selectively irradiated by the first energy beam 4. The evaluation information may describe/indicate diverse chemical and/or physical parameters being directly or indirectly related to the cooling behavior of the portion of the layer 2 of build material 3 which was selectively irradiated by the first energy beam 4. The evaluation information can be communicated to diverse functional devices of the apparatus 1 by means of communication links between these functional devices. The evaluation information can be communicated to a user interface device 22, e.g. a screen, of the apparatus 1 and hence, output to a user.
The control device 23 may be configured to control operation of the irradiation device 8 on basis of an evaluation information determined by the evaluation device 14. Hence, by controlling operation of the irradiation device 8 on basis of a respective evaluation information, the first and/or second energy beam 4, 9 may be controlled in such a manner so as to achieve a desired cooling behavior of portions of layers 2 of build material 3 which were selectively irradiated by the first energy beam 4 and therefore, a desired microstructure within the three-dimensional object to be additively built. Controlling operation of the irradiation device 8 and thus, of the cooling behavior may be implemented as a control-loop allowing for a real-time control of the cooling behavior and other factors influencing the quality of the additively manufactured object.
By means of detecting radiation 12 emitted or reflected from portions of a layer 2 of build material 3 which was selectively irradiated by the first energy beam 4 and evaluating detected radiation 12 with regard to the cooling behavior of the respective portion of the layer 2 of build material 3 which was selectively irradiated by the first energy beam 4, the apparatus 1 allows for a reliable and, in particular highly integrateable, determination of the cooling behavior of respective selectively consolidated portions of layers 2 of build material 3 which have been selectively irradiated during an additive manufacturing process.
According to the exemplary embodiment given in the Fig., the irradiation device 8 comprises a first beam generation unit 15 configured to generate the first energy beam 4 and a second beam generation unit 16 configured to generate the second energy beam 9. Yet, the irradiation device 8 could also comprise only one beam generating unit configured to generate an energy beam (which is split so as to generate the first and second energy beam) and an associated beam splitting unit (not shown) configured to split the energy beam generated by the beam generating unit so as to generate the first and second energy beam 4, 9.
According to the exemplary embodiment given in the Fig., the irradiation device 8 comprises a first beam deflection unit 17 assigned to the first energy beam 4 so as to deflect the first energy beam 4 to different positions of a layer 2 of build material 3 and a second beam deflection unit 18 assigned to the second energy beam 9 so as to deflect the second energy beam 9 to different positions of a layer 2 of build material 3. Each beam deflection unit 17, 18 comprises a number of, particularly moveably supported, beam deflection elements (not shown), e.g. deflection mirrors.
The irradiation device 8 further comprises two beam guidance units 19, 20, whereby a first beam guidance unit 19 is configured to guide the first energy beam 4 along an optical path extending from the first energy beam generation unit 15 to the first beam deflection unit 17 and a second beam guidance unit 20 is configured to guide the second energy beam 9 along an optical path extending from the second energy beam generation unit 16 to the second beam deflection unit 18. As is discernible from the Fig., the detection device 11 is assigned to the second beam guidance unit 20. In particular, the detection device 11 is arranged in an on-axis arrangement with respect to the second beam deflection unit 18. A respective on-axis arrangement of the detection device 11 allows both in constructive and functional regard for a highly integrated arrangement of the detection device 11. A respective on-axis arrangement of the detection device 11 further allows for obtaining high-dynamic and high-resolution detection information, e.g. high-dynamic and high-resolution detection images, of the detected portions of respective layers 2 of build material 3. A respective on-axis arrangement of the detection device 11 also allows for obtaining coordinate values, etc. of respective detected information.
The second beam guidance unit 18 may comprise at least one optical element 21, e.g. a semi-reflective mirror element, configured to guide radiation 12 emitted from a portion of a layer 2 of build material 3 which was selectively irradiated by the first energy beam 4 to the detecting device 11. Hence, the same optical path can be used for an energy beam 9 and for the radiation 12 emitted from a portion of a layer 2 of build material 3 which was selectively irradiated by the first energy beam 4. The direction of extension of the radiation 12 emitted from the portion of the layer 2 of build material 3 through the optical path built by the second beam guidance unit 18 is at least partly a reverse direction of extension of the energy beam 9 through the optical path.
The detection device 11 or a further detection device (not shown) may be configured to additionally detect radiation emitted from a portion of a layer 2 of build material 3 which is currently selectively irradiated by the first energy beam 4. In such a manner, not only the cooling behavior of portions of layers 2 of build material 3 which were selectively irradiated by the first energy beam 4, but also the fusing behavior of portions of layers 2 of build material 3 which are currently selectively irradiated by the first energy beam 4 can be detected.
In either case, the evaluation device 14 or a further evaluation device may be configured to evaluate detected radiation emitted from a portion of a layer 2 of build material 3 which is currently selectively irradiated by the first energy beam 4 with regard to the fusing behavior of the portion of the layer 2 of build material 3 which is currently selectively irradiated by the first energy beam 4. The (further) evaluation device 14 may comprise at least one evaluation algorithm configured to evaluate detected radiation emitted from a portion of a layer 2 of build material 3 which is currently selectively irradiated by the first energy beam 4 with regard to the fusing behavior of the portion of the layer 2 of build material 3 which is currently selectively irradiated by the first energy beam 4.
The apparatus 1 is configured to implement a method for additively manufacturing three-dimensional objects by means of successive layerwise selective irradiation and consolidation of layers 2 of a build material 3 which can be consolidated by means of an energy beam 4. The method comprises the steps of generating at least two energy beams, 4, 9, whereby a second energy beam 9 follows the path of a first energy beam 4 with a defined offset; detecting radiation emitted 12 from a portion of a layer 2 of build material 3 which was selectively irradiated by the first energy beam 4; and evaluating detected radiation 12 emitted from the portion of the layer 2 of build material 3 which was selectively irradiated by the first energy beam 4 with regard to the cooling behavior of the portion of the layer 2 of build material 3 which was selectively irradiated by the first energy beam 4.
| Number | Date | Country | Kind |
|---|---|---|---|
| 17186481.2 | Aug 2017 | EP | regional |
