Patent Application
20250214144
The invention relates to a method and an apparatus for the powder bed fusion process and to a storage medium including instructions to execute the method.
There are a number of additive manufacturing techniques, as well referred to as 3D- printing processes. One of these techniques is the so-called powder bed fusion process. Very briefly summarizing, the powder bed fusion process consists of iteratively applying a powder layer onto a support structure and selectively adhering powder particles to another or previously adhered agglomerates by heating the respective particles using an electron beam, a laser beam or any other kind of radiation beam (hereinafter jointly “beam” for short). Adhering particles of a powder bed by scanning a surface of the powder bed with a beam is referred to as fusing, regardless of the physical or chemical process (melting, sintering, welding, radiation induced chemical reaction, . . . ) that provides the result of adhered particles. Vividly speaking, sectional views of the product to be manufactured are so to speak written and thus formed on each newly applied top layer by moving a beam spot over the surface of the upmost powder layer. The area of the powder bed in which the section view is formed may hence be considered as a forming region or a fusing region. By adding a new powder layer after each writing step a so-called powder bed is formed. Embedded in the powder bed is the already manufactured portion of the workpiece. Depending on the final product, sometimes additional auxiliary structures have to be “written” into the powder layer, but herein we do not focus on this aspect and we consider these to be a part of the workpiece. Once all layers have been written, the workpiece, potentially with its adhering auxiliary structures, may be removed from the powder bed and may be subjected to further processing, if required. The terms product and workpiece are used interchangeably in this field and hence herein.
The powder bed fusion process is very capable, but it is desirable to reduce the manufacturing times for a given workpiece. To this end, it has been suggested to use multiple beams which independently write a portion of each layer (i.e. a portion of the “sectional view”) of the workpiece onto each layer of the powder bed. Further, in particular in case the up-facing surface of the powder is increased to manufacture larger workpieces, multiple beams sourced can be distributed at different locations above the powder bed to reduce imperfections due to beam expansion and parallaxes. This approach, however, has limitations, for example fumes being produced by a first beam may interfere with another beam, which is detrimental to the quality of the product. Other problems are related to heat dissipation in the powder bed or to beam spot distortion. Beam spot distortion describes the effect of an increasing elliptic distortion of the beam spot formed on the powder bed as a function of increasing deviation of the angle of incidence from a near normal incidence.
WO 2016/075026 A suggests optimizing a multi beam laser powder bed fusion process by virtually separating the surface of a powder bed into a number of surfaces sections, wherein each beam illuminates and hence fuses powder particles in a single surface section being assigned to said beam. Once all beams finished writing on a layer, i.c. when the next powder layer can be applied to the powder bed, the run-times of each beam source, as well referred to as “beam-on times” of the different beam sources are compared and the boundaries between the surface sections are adjusted to compensate for differences in the run times. For example, if beam source No. 1 has a lower beam-on time than beam source No. 2, when writing the layer No. l, the boundary between the surface sections being associated to beam sources No. 1 and No. 2 are shifted to increase the surface area of the surface section associated to beam source No. 1 and to decrease the surface section associated to beam source No. 2. Thereby, idle times of the beam sources are reduced when fusing the next layer, i.e. layer No. l+1. Alternatively, the areas of the actually illuminated surfaces may be compared and based on the comparison the boundaries between the surface sections may be adjusted to compensate for differences in the actually illuminated surfaces.
WO 2020/178216 A suggests controlling the positions of the beam spots of a multi beam laser powder bed fusion process such that at—no point in time—any line connecting two beam spots is parallel to a flow direction of an inert gas flow over the powder bed.
DE 10 2013 205 724 A1 suggests improving the powder bed process by coordinating the direction in which the beam of a beam source scans a portion of the powder bed and the inert gas flow direction. This coordination can be obtained by limiting the angle of the scanning direction and the inert gas flow direction to the interval [22.5°, 337.5°], preferably to the interval [90° and 270°].
DE 10 2018 203 233 A1 suggests scanning a sectional view of a workpiece in the powder bed process by at least two lasers. Each laser is assigned a region of the sectional view, i.e. the respectively assigned region is scanned by the corresponding laser. The boundary between of these two neighbored regions of the sectional view is saw tooth line, to thereby increase the strength of the manufactured workpiece.
W0 2016/110 440 A1 as well relates to a multiple beam powder bed process. Each beam has a field of view and at least two of these fields of view are overlapping. To improve scanning speed, it is suggested to locate the sectional view to be irradiated by the beams at least in part in a portion of the powder bed in which the fields of view of at least two beams are overlapping. The sectional view is scanned by the beams at the same time, wherein the distance between the spots being irradiated at the same time is reduced over time until the irradiated spots of the beams at least partially, preferably fully overlap. The beam intensities are reduced with an increase of the overlap to maintain the energy being provided to each spot of the sectional view being scanned constant.
The object of the invention is thus to further improve the multi beam powder bed fusion process with the object of reducing the cost for manufacturing a workpiece.
The invention is based on the observation that the prior art suggestions for defining the boundary between two adjacent surface sections of the surface of a top layer of a powder bed is based on the beam-on times measured when writing the previous layer. This process iteratively finds the optimum boundary position and hence leads to a significant cumulation of idle times. This approach is further increasingly inefficient, the more the surface areas to be illuminated in the different surface sections change from layer to layer.
The method for manufacturing a workpiece includes fusing an area A (“the area A”, for short) of a surface of a layer of a fusible material (“the layer”, for short). In practice, the layer may be the present upmost layer of a powder bed on top of a powder bed support of an additive manufacturing machine configured to use and/or to implement the powder bed fusion process. Once the area A of the of the top layer intended to be fused have been fused, the next layer may be applied to the powder bed, e.g. using a recoater. Initially, the upmost layer may be the first layer of the powder bed being subsequently deposited during the process.
As already apparent the term “area” does not necessarily denote the entire surface of the layer, but only a portion thereof that shall be fused. The symbol A thus represents a set of locations (points) that can be represented as vectors {right arrow over (p)}, all in the plane defined by the surface of the layer, which shall be and during the process are irradiated by at least one beam spot being emitted by a beam source. The symbol |A| hence symbolizes a value indicative for the size of the surface of the aera A, i.e. |A| is the surface area of the area A. Using the skilled person's language|A| is a norm, generally referred to as ||A||, only for simplicity we omit herein the second set of vertical bars.
The area A may be the entire area EA of the layer to be irradiated, but in another example, the area A may be only a portion thereof, i.e. A⊆EA. For example, those parts of the entire area EA to be irradiated that define, e.g., a portion of the contour of the workpiece may be subtracted from the entire area to thereby obtain “the area A”. The contour portions being subtracted may, for example, be irradiated always by the same beam source to increase the quality of the workpiece surface defined by said contour. Alternatively, or in addition, the ‘entire area’ EA may be divided in subareas, e.g. to improve fume management. As already stated “the area A” may be a subarea of the ‘entire area EA’. Generalizing, one may thus say that the area A may be at least a portion of a sectional view of the workpiece to be manufactured by application of the laser powder bed fusion process, wherein the section plane corresponds to the position of the layer of fusible material to be irradiated.
The area A may include multiple subareas, we call sectors to distinguish the sectors verbally from the previously discussed ‘subareas of the entire area to be irradiated’. The sectors may by spaced from each other, i.e. there may be a gap between neighboured sectors of the area A. Further, as already apparent, it is irrelevant for the invention to which layer the area A is associated. All that is required is that the area A can be irradiated by beams being emitted by the beam sources. When referencing to an area A on a particular layer, the symbol Al may be used. Thus A1 would be an area on the first layer of a powder bed, A2 an area of subsequent layer of the powder bed, Al is an area on the lth-layer. If the up script is omitted this means that the position of the Area A in the sequence of layers is not relevant and may take any number.
The area A is typically determined by a so called “slicer” based on a CAD-model of the workpiece to be manufactured. But the invention is not limited to this example.
As already apparent from the wording fusing a surface area A of a layer of a fusible material, the method includes fusing the portion of the fusible material of the layer as defined by the surface area A. To this end at least two spots of at least two beams are projected by at least two beam sources onto the set of locations defining the surface area A. The method can be used in case there are only two beam sources, but practice the number may be higher. Typical values are, depending on the size of the layer, between 8 to 12, but the invention is not limited to this range. Future powder bed fusing apparatuses are expected to have even higher numbers of beam sources. Herein we symbolize the total number of beam sources being available by “n”. This number “n” of beam sources being available may be different from the number of beam sources of the powder bed fusion apparatus. For example, if one or more beam sources has or have been assigned the task of fusing a contour portion which is not a portion of the area A, then these assigned beam source(s) cannot contribute to fusing the area A, while fusing the respective contour portion(s). Once the assigned contour portions have been fused, these beam sources can be used to fuse sections of the area and the number “n”, hence can be increased. Another ground for a number “n” being smaller than the number of installed beam sources may be to reduce the thermal power that needs to be removed from the workpiece or simply because a section of the area would be so small that location management would be difficult. For example, if a section is very small, it can become almost impossible to avoid fusing the section while not operating in a smoke plume being produced by fusing the powder bed in another section. Thus, is short, the number “n” represents the number of lasers being assigned to jointly fuse an area A. As will become apparent below, the number may even change during the process of assigning locations of the area A to the sets of locations Li (1≤i≤n) which may then be fused by the corresponding i{circumflex over ( )}th-beam source. This may, e.g., happen if it turns out that the size of the area of a set of locations Li would be below a predefined threshold Ti.
Each of the n, (n≥2) beam sources has a predefined field of view Fi, wherein the index i indicates the corresponding ith-beam source, e.g. F1 is the field of view of the first beam source, F2 is the field of view of the second beam source, or more generally Fi is the field of view of the ith-beam source. The field of view Fi is the surface portion of the layer that can be irradiated by the corresponding ith-beam being emitted by the ith-beam source. In practice, each field of view Fi may be defined by a scanner optic of the ith-beam source. Constraints in the field of view Fi may be imposed by pivot ranges of a scanner optic, limits of (optional) focussing optics and as well by a limit of the acceptable beam distortion. In general, the field of view Fi can be understood as the portion of the layer that can be reasonably fused using the corresponding ith-beam source. The field of view Fi can thus be expressed as set of vectors {right arrow over (f)}i on the surface of the layer that can be irradiated and hence fused using the ith-beam source. Thus, |Fi| is the size of the portion of the surface of the layer that can be irradiated by the corresponding ith-beam source. Further, each beam source i has a predefined fuse rate Ri (a positive real number), wherein the fuse rate indicates the size of the surface field of view that can be fused by the ith-beam source per unit of time. The fuse rate Ri is a surface area per time and hence can be measured, e.g.
or the like. For example, when fusing a surface, the beam spot often travels along a first vector, defining a first fuse trace until a stop condition is reached. Then the beam may be switched off and the beam source may be repositioned to a new start point. Next, the beam may be switched on again and the beam spot travel may travel, e.g. parallel to the previously fused fuse trace. Calculation of the fuse rate Ri may thus account for the time being required to reposition the beam source. In practice the fuse rate Ri can be considered as a mean fuse rate that may be determined iteratively with an increasing accuracy. The fuse rates Ri may differ between different beam sources and may as well depend on a given material to be fused. At least for a given material, the fuse rates Ri are preferably at least almost the same, meaning that (1±βR
In another example, the fuse rate Ri is simply the length (times the width) of a trace the ith-laser scans per unit of time without accounting for the time required to reposition laser beam optics when starting a new trace.
Fusing the area A may include irradiating different sets Li of locations {right arrow over (l)}i on the layer using the ith-beam source for the corresponding set of locations Li, wherein the intersection of different sets of locations may preferably be empty, i.e. preferably the relation Li∩Lj={}=0, ∀i≠j holds. This means essentially, that each location {right arrow over (p)} of the area A may be fused only by a single beam source. Generally, it is preferred to use all beam sources of the powder bed fusing apparatus for fusing the area, but this is not required and, in some cases, not even possible (as explained above). Of course, the different sets of locations Li may be irradiated at the same time. In practice the trajectories of the projections of the beam spots of different beams sources may overlap, e.g. similar to the overlapping of sections of a single beam's trajectory to ensure a given strength and surface quality in those regions of the layer, where the final workpiece shall not have a gap. There have been suggestions to fuse using overlapping sets of locations, but herein this is-although not excluded-not intended. Intended is |Li∩Lj|≤βL·Max({|Li|, |Lj|}), wherein
preferably βL=0. Thus, generally, it may be intended to separate the area A into a number n sets of locations Li, wherein n indicates the number of beam sources that shall be used. Preferably, n indicates the number of beam sources having a field of view with a non-vanishing overlap with the area A, i.e. the number of different indices for which Fi∩A≠{} in another example n indicates the number of beam sources having a field of view with an overlap with the area A being greater than a threshold T, i.e. only those beam sources are considered for which |Fi∩A|≥Ti.
Preferably, prior to fusing the area A, an optimum fusing time to(i) may be determined (step 1.1). There are a number of possibilities to estimate an optimum fusing time to(i), and in a preferred example the optimum fusing time can be determined by dividing the size of the area |A| by the sum of the fuse rates Ri of all involved beam sources, hence
In this case all beam sources would require the same amount of time to fuse their respective sets of locations Li, i.e. idle times are minimized. Other estimations may be used as well. For example, one may use
or
wherein
preferably βt,i=0. Generalizing, any suited measure for an optimum fusing time to(i) can be chosen, preferably to(i) may be selected to obey
Thus, the optimum fusing time depends on the size of the surface area |A| to be fused, following the convention that an upscript indicates the number of a layer the optimum fusing time may as well be indicated as tol(i). Unless required we will omit the upscript as well as the indication of the associated beam source “(i)” for simplicity.
Equivalent to determining the optimum fusing time to(i), one may as well or in addition determined the optimum size of a corresponding fusing area |Liopt|. In a preferred example |Liopt|=to(i)·Ri.
In addition, at least a first intersecting set IS1 of the surface area A and the first field of view (F1) of a first beam source may be determined, hence IS1:=A∩F1. (step 1.2). This is equivalent to determining those vectors of the area A on the surface of the layer that generally could be irradiated and hence subjected to fusing by the 1st-beam source. Further intersecting sets ISi may be determined as well, wherein ISi is the intersecting set being associated to the ith-beam source. In an example, ISi may generally be defined as ISi=A∩Fi∀1≤i≤n. But as will be apparent below, other definitions may be used as well. Further, it should be noted, that an intersecting set ISi, i≥2 may preferably be determined after the set of locations Li−1 has been determined as explained below. (Only for formal simplicity one may define L0:={} or more generally Lj:={}∀j≤0, ∀j>n.
In a further step, the size of at least the first intersecting set |IS1| is compared to the product of the optimum fusing time to(i) with the fuse rate Ri of the corresponding ith-beam source (step 1.3) and if the relation
to(i)·Ri<|ISi| holds true, then a subtrahend surface S1 with S1⊂IS1 and at least one of (1−α1)·(|IS1−to(i)·R1)≤|S1|≤(1+α1)·(|IS1|−to(i)·R1) and its equivalent (1−αi)(|IS1|−|L1opt|)≤|S1|≤(1+α1)(|IS1|−|L1opt|) may be determined wherein the condition that for each
{right arrow over (p)}1∈S1, ∃Fk|{right arrow over (p)}1∈Fk, k∈{2, . . . , n} may be observed (step 1.3.1). α1 can be considered as an error margin (hence α1=0 is preferred) and is defined below in detail.
Again, by replacing the index 1 by the index i, the step may be generalized to obtain the ith subtrahend surface Si being associated to the ith-beam source, i.e. generalizing in case the condition to(i)·Ri<|ISi| holds true, the ith-subtrahend surface Si may be determined using the conditions Si⊂ISi and (1−αi)·(|ISi|−to(i)·Ri)≤|Si|≤(1+αi)(|ISi|−to(i)·Ri) (and/or (1−αi)(|ISi|−|Liopt|)≤|Si|≤(1+αi)(|ISi|−|Liopt|)) that for each {right arrow over (p)}i∈Si, ∃Fk|{right arrow over (p)}i∈Fk, k>i} may be obeyed, wherein αi∈{0.25, 0.2, 0.15, 0.1, 0.05, 0.025, 0.01, 0.005, 0}. Smaller values of αi are preferred, in a particular preferred example αi=0. If αi=0, then the constraint on |Si| simplifies to |Si|=|ISi|−to(i)·Ri. These constraints on Si enable to determine any Li=ISi−Si, and to thereby determine a set of locations Li which can be expected to be fused by the ith-beam source almost exactly within the preselected optimum fusing time to(i). Thus, if all sets of locations {Li} are, e.g., iteratively determined as explained above these are be selected such that the time for fusing the area may be minimized. This minimization is due to the fact the suggested determination of the sets of locations {Li} ensures, that within the error margins given by the βt,i and αi it can be expected that all beam sources require the same amount of time to fuse their respective set of locations Li. Idling of beam sources is minimized. It should be noted that it is not required to determine all Li as suggested. For example the nth set of locations Ln can be determined using Ln=A−Σi=1n−1Li because A=Σi=1nLi.
Herein, we assume that the steps are reiterated for every i≤n, starting with the lowest value of i=1 and then within each iteration the value is increased by one, i.e. prior to each repetition of step 1.1 or 1.2, i:=i+1 is executed, but this is only for conceptual simplicity, as Ln=A−Σi=1n−1Li. Hence, it is sufficient to execute the steps only n−1 times and still obtain the same result. The condition ∀{right arrow over (p)}i∈Si, ∃Fk|{right arrow over (p)}i∈Fk, k>i is based on the assumption that the subtrahend surfaces Si are determined in ascending order, i.e. that i increases by one after a subtrahend surface Si has been determined for particular i. This sequence is not necessary, but if it is released the condition “k>i” would read “wherein i may take any value for which a subtrahend surface Sk has not yet been determined”. Both wordings are equivalent, as by renumbering the beam sources the same sequence of determining the subtrahend surfaces Si can be obtained, while taking care that the index i steadly increases by 1 after a particular subtrahend surface has been determined.
Of course, the method can be repeated for each layer and hence the time for manufacturing a workpiece is minimized. For a given powder bed fusing apparatus, the cost for manufacturing the workpiece is reduced.
To reiterate it vividly, the subtrahend surfaces Si are thus subsets of vectors of the area A, being selected such that the expected time <ti> for irradiating the surface given by the set of locations Li:=ISi−SI equals the optimum fusing time to(i) with an accuracy being given by the selection of αi, βt,i. Assuming that to(i)·Ri<|ISi| is true for all i and α=0 as well as βt,i=0 then <ti>=to(i)∀i, i.e. the total time ttot being required to fuse the area A using the n beam sources simultaneously is ttot=Max(to(i)) and identical to the lower limit being inherent to the apparatus and the material to be fused. At this point it should be recalled that in practical applications, a workpiece may have thousands of layers, and thus small savings in irradiating an area on each layer accumulate to non-negligible cost savings.
Once Si has been determined for a given i, the ith-set of locations Li can be determined using Li:=ISi−Si (step 1.3.2) and the method may proceed with fusing the corresponding set of locations of Li using the ith-beam source (step 1.4). Before continuing to execute step 1.4, preferably at least the steps 1.2 to 1.3.2 are repeated for each other beam source, i.e. for all remaining beam sources (1<i≤n). Step 1.4 may be preferably executed for at least two different Li, Lj, (i≠j) at the same time. The higher the number of beams that are irradiating their correspondingly assigned surfaces Li simultaneously the better. Preferably, all n beam sources irradiate at the same time.
In case the size of a section Li is below a given threshold, e.g. below the threshold Ti explained above, the section Li may be set to zero (Li:={}), which is equivalent to reducing the number of beam sources to n−1, i.e. an ith-beam source may be removed from the pool of n beam sources, if |Li|<Ti.
There may be cases in which the overlap between the area A and a field of view Fi is so small that the time required to irradiate the corresponding interesting set ISi=A∩Fi is smaller than the optimum time to(i), in this case to·Ri>|ISi| is true. In this case one could simply assign Li:=ISi, but in practice it may be necessary to have a defined shape of Li or that Li does not extend in predefined sectors of the area A. Thus, more generally, a subtrahend surface Si is defined with Si⊂ISi under the condition that for each {right arrow over (p)}i∈Si, ∃Fk|{right arrow over (p)}i∈Fk, k>i. Further, in the case of to·Ri>|ISi| then |Si| may preferably be minimized. Once Si hast been determined, the set of locations Li to be irradiated by the ith-beam source is determined using Li:=ISi−Si, i.e. the method may continue to step 1.4.
The condition “for each {right arrow over (p)}i∈Si, ∃Fk|{right arrow over (p)}i∈Fk, k>i” reads in plain language that for each vector {right arrow over (p)}i which vector {right arrow over (p)}i is an element of the subtrahend surface Si exists at least one field of view Fk such that the field of view Fk includes the vector {right arrow over (p)}i, wherein the index k is larger than the index i. This condition ensures that any point/location of the area A being removed from the intersecting set ISi can be irradiated by at least one other beam source for which the set of locations Lk has not yet been determined, the latter following from k>i. Any location of the area A which can be fused by only by a limited number of beam sources forming a set of indices X may thus be assigned at latest to a set of locations LMax(X) with the highest index of said set X.
The corresponding expectation value of the time for irradiating the surface of the layer with the ith-beam source reads identically to the other case <ti>=Li/Ri. Generalizing, one may say that in case to·R≥|ISi|,i.e. in the “ELSE” case of step 1.3 (i.e. if (to·Ri≥|ISi|), steps 1.3.1 and 1.3.2 may be executed while the condition (1−αi)·(|ISi|−to·Ri)≤|Si|≤(1+αi)·(|ISi|−to·Ri) may be released.
Preferably, particularly in case to·Ri≥|ISi| (but generally in any case), a corrected minimum time to(i+1), as well referred to as t′o may be calculated in a subsequent iteration of step 1.1 (i.e. after setting i:=i+1) using e.g.
The corrected minimum time may then be used in future executions of steps 1.3 to 1.3.2 and instead of an initially calculated or estimated optimum fusing time. This adjustment of the optimum time to(i) enhances an even load distribution between the beam sources for which the set of locations has not yet been determined, i.e. the variation of |Lj| (i<j≤n) is reduced. This provides a further increase in efficient use of the apparatus' capabilities and hence translates in lower manufacturing costs of a corresponding workpiece.
The step of calculating a corrected minimum time can be generalized by recalculating a (corrected) minimum optimal time with each iteration, i.e. in step 1.1 to(i) may be
being equivalent to
wherein if i=0 the term Σj=1i−1|Lj|:=0 and hence
Again, the preferred case may be βt(i)=0 and i indicates the ith-execution of the steps. As already apparent, βt,i as defined above serves as an error margin and to(i) may be selected to be within boundaries being given by selection either the “+” or the “−” of “±”. Generally, βt,1=βt(i) can be different for every iteration only for simplicity we will write βt as well. The of step calculating a corrected minimum time may be particularly useful if the effects of non-negligible αi sum up. In short both possibilities account for a potential difference between the optimum mean fusing time to and the actually expected fusing times <ti>=|Li|/Ri for each iteration of the calculation of Li. If not addressed, these differences may lead to the situation that |Ln| may be significantly bigger that all other Lj, (1≤j<n), and hence significant idle times of the beam sources 1 to n−1 reduce the efficiency of the additive manufacturing process. Thus, again the step of recalculating an updated optimum mean fusing time further contributes to reducing the operating costs per workpiece.
In case the size of a section Li is below a given threshold, e.g. below the threshold Ti explained above, the section Li may be set to zero (Li:={}), which is equivalent to reducing the number of beam sources to n−1, i.e. an ith-beam source may be removed from the pool of n beam sources, if |Li|<Ti. Of course, in this case it may be preferred to calculate a corrected minimum time and/or a corrected optimum size of a corresponding fusing area |Liopt|.
The threshold Ti may be defined for each ith-beam source individually. It may as well be set manually for each beam source individually or for all or a number of beam sources, e.g. based on the experience of an operator. In a preferred example, the threshold Ti may be a set portion of the optimum size of the fusing area |Liopt|, e.g. Ti=cT
cT
Preferably, the method may further include to define at least a first (preferably meandering) line Bi,j and preferably as well a second (preferably meandering) line Bi,k, wherein the first (preferably meandering) line Bi,j extends (preferably meanders) in a first direction {right arrow over (b)}1 and the second (preferably meandering) line Bi,k extends (preferably meanders) in a second direction {right arrow over (b)}2 (step 4.1). The first (preferably meandering) line may be used to limit the extension the subtrahend surface Si in a direction being at least essentially orthogonal to the first direction {right arrow over (b)}1. Similarly, the second (preferably meandering) line may be used to limit the extension the subtrahend surface Si in a direction being at least essentially orthogonal to the second direction {right arrow over (b)}2. At least one of the first and second (preferably meandering) lines hence determines a first boundary of the subtrahend surface Si (step 4.2). At least one of these first and second (preferably meandering) lines may be shifted to reduce ΔSi, wherein ΔSi=|to(i)·Ri−|ISi−Si|. Further preferably, when determining an Sj after another Si (i.e. i<j) and if the ith-beam source and the jth-beam source are neighbours (or at least have overlapping fields of view), then Bj,i=Bi,j.
During this shifting, the first (preferably meandering) line Bi,j may preferably be shifted at least essentially orthogonal to the first direction {right arrow over (b)}1 and/or the second (preferably meandering) line may preferably be shifted at least essentially orthogonal to the second direction {right arrow over (b)}2 to reduce ΔSi, preferably until the condition 1.3.1 is met. As already apparent the two vectors {right arrow over (b)}1, {right arrow over (b)}2 are preferably linearly independent (condition 5), and particularly preferred they may be at least essentially orthogonal to each other, i.e. preferably {right arrow over (b)}1⊥{right arrow over (b)}2. Exceptionally the indices of the vectors {right arrow over (b)}1, {right arrow over (b)}2, . . . are not associated with a beam source, these serve only to distinguish these vectors. The indices of the lines Bi,j however are preferably associated to two beam sources, namely to the ith- and to the jth-beam source, after determining all Li, the (preferably meandering) line Bi,j separates the sets of locations Li and Lj.
A line Bi,j meanders along or in the direction {right arrow over (b)}1 if the line Bi,j has a first end point {right arrow over (b)}i,j,e that obeys the condition |{right arrow over (b)}1·({right arrow over (b)}i,j,l−{right arrow over (b)}i,j,e)|≠|{right arrow over (b)}1·({right arrow over (b)}i,j,m−{right arrow over (b)}i,j,e)|∀{right arrow over (b)}i,j,l,{right arrow over (b)}i,j,m∈Bi,j,{right arrow over (b)}i,j,l≠{right arrow over (b)}i,j,m and if |{right arrow over (b)}⊥·({right arrow over (b)}i,j,l−{right arrow over (b)}i,j,e)≠|{right arrow over (b)}⊥·({right arrow over (b)}i,j,m−{right arrow over (b)}i,j,e)|∀{right arrow over (b)}i,j,l,{right arrow over (b)}i,j,m∈Bi,j,{right arrow over (b)}i,j,l≠{right arrow over (b)}i,j,m with {right arrow over (b)}⊥⊥{right arrow over (b)}1 does not hold true.
Fusing the fusible material at the set of locations Li may include pivoting the ith-beam source while the ith-beam source projects an ith-beam spot to thereby move the ith-beam spot along lines being multiples of a vector {right arrow over (v)}i. In a preferred example, the meandering lines include or consist of concatenated sections being, in alternating sequence, perpendicular to {right arrow over (v)}i or parallel to {right arrow over (v)}i (step 6).
Particularly preferred, the method further includes to execute the steps 1.2 and 1.3 (and optionally of course as well all other steps) first for the beam source that has a field of view which has the least overlap with the fields of view of other beam sources. Next, the steps are executed for the beam source which field of view has the second least overlap with other fields of view and so. This helps to reduce the computational effort when calculating the corresponding subtrahend surfaces Si, as in this way first those portions of the area are assigned to a set of locations Li that in the worst case can be irradiated only by a single beam source, which may—if not accounted for—yield to the situation that a single beam source operates much longer than the others. Executing the steps 1.2 and 1.3 (and optionally of course as any of the other steps) first for the beam source that has a field of view which has the least overlap with the fields of view of other beam sources and so on may be obtained by sorting the indices of the beam sources such that the first (i=1) beam source has the field of view F1 that has the least overlap and second (i=2) beam source has the field of view F2 with the second least overlap and so forth. In other words, this means that preferably initially, but at latest prior to step 1.2 the indices of the fields of view Fi are preferably sorted to obey the condition
Min(Σji≠jFi∩Fj)≤Min(Σji+1≠jFi+n∩Fj)∀i<n and that at least the steps 1.2 and 1.3 are repeated while increasing the value of the index with each repetition by one until the index i=n. Of course, for those Fi for which Fi∩A={} sorting can be omitted as it is clear that the corresponding set of locations Li is empty, i.e. Li={}.
In addition or alternatively, the method may include (as well prior to step 1.2), sorting the indices of the fields of view Fi to obey the condition |Fi∩A|≤|Fj∩A|∀i<j and that steps 1.2 and 1.3 and optionally at least one of the steps REF _Ref65147212\r\h\* MERGEFORMAT 2.1 to 2.3 are repeated while increasing the value of the index with each repetition by one. Again, the position of the beam sources having an index i for which Fi∩A={} can be selected arbitrarily. As well, this sorting step cases determining the subtrahend surfaces Si, while maintaining the error margin αi small, i.e. to reduce avoidable idle times of beam sources that generally could contribute to fusing the area A.
The method may further include, prior to determining a subtrahend surface Si to assigning a portion Ci of the area A to a dedicated ith-beam source. In practice the beam sources are calibrated to operate all in the same coordinate system. This calibration, however, is not perfect and can deteriorate during the process of manufacturing. When assigning particular portions Ci of the area A a priori to a certain dedicated ith-beam source, imperfections of the workpiece can be reduced in this portion Ci, thus Ci⊂Fi, i.e. the portion Ci is within the field of view Fi. Normally, such an assignment increases the total manufacturing time, because the load distribution between the different beam-sources is deteriorated. In an embodiment, this deterioration can be avoided by considering the additional constraint Si∩Ci={} when determining the subtrahend surface Si, e.g. in steps 1.3.1 and/or 2.1. Obeying the additional constraint Si∩Ci={} ensures, that the portion Ci is a subset of the subsequently determined set of locations Li being later irradiated by the ith-beam source, and that the additional size of the set of locations Li being due to the portion Ci is considered in the load balancing constraint
In an embodiment, when repeating step 1.2, the intersecting sets ISj (j≥2) are determined as ISj:=(A−Σi=1i<jLi)∩Fj. This step provides a number of advantages: The memory requirements are reduced and further determining a suited subtrahend surface Si is significantly simplified, leading to further cost optimizations. The idea underlying this improvement is that those portions of the field of view Fi that already have been assigned to sets of locations Li, (i<j) in previous executions i of at least one of the steps 1.2 to 1.3.2 and/or 1.2 to 2.3 do not need to be included in further considerations. As Σi=11<0Li=0, the condition j≥2 can be released, i.e. ISj may be defined as ISj:=(A−Σi=1i<jLi)∩Fj∀j∈I∀j∈I
During the fusing process, i.e. during operation of the beam sources it may be preferred to establish an inert gas flow over the top of the powder bed to thereby remove fumes and other residues out of the fields of view Fi. Preferably, a flow in a flow direction parallel to the top surface of the layer may be established, e.g. by arranging at least one inlet nozzle at a first side of the top layer and at least one outlet nozzle at the opposite side of the top layer and by establishing an inert gas flow from the inlet nozzle to the outlet nozzle, thereby defining a main flow direction. In other words, the method may further include establishing an inert gas flow in a flow direction {right arrow over (d)} over the top of the powder bed, wherein {right arrow over (d)}h denotes the (preferably normalized) component of the flow direction being parallel to the layer of fusible material, i.e. the projection of the flow direction {right arrow over (d)} onto the area A. For example, if the z-axis is perpendicular to the surface of the layer of fusible material (and hence to the area A), then using cartesian coordinates
wherein (dx2+dy2)−1/2 is only a normalization factor setting |{right arrow over (d)}h|=1, and can be omitted. As usual dx, dy and dz are the x-, y- and z-components of the vector {right arrow over (d)}, respectively.
This flow direction parallel to the layer {right arrow over (d)}h may preferably be correlated with the extension of the meandering lines Bi,j limiting the subtrahend surfaces Si and which define the boundary between adjacent sets of locations Li and Lj such that the boundary Bi,j between two sets of locations Li and Lj has a first end point {right arrow over (b)}i,j,e that obeys the condition |{right arrow over (d)}h·({right arrow over (b)}i,j,l−{right arrow over (b)}i,j,e)|≠|{right arrow over (d)}h·({right arrow over (b)}i,j,m−{right arrow over (b)}i,j,e)|∀{right arrow over (b)}i,j,l,{right arrow over (b)}i,j,l≠{right arrow over (b)}i,j,m (condition 13.1). This means that any distance between the first end point {right arrow over (b)}i,j,e and any other point {right arrow over (b)}i,j,l of the boundary Bi,j exists only once. Hence, any subsection of Bi,j has a non-vanishing extension in the direction defined by the horizontal component of the flow direction {right arrow over (d)}h. In this case the relation |{right arrow over (d)}o·({right arrow over (b)}i,j,l−{right arrow over (b)}i,j,e)≠|{right arrow over (d)}o·({right arrow over (b)}i,j,m−{right arrow over (q)}e)|∀{right arrow over (b)}i,j,l,{right arrow over (b)}i,j,m∈Bi,{right arrow over (b)}i,j,l≠{right arrow over (b)}i,j,m (condition 13.2) with {right arrow over (d)}o⊥{right arrow over (d)}h dn is preferably not realized, thus Bi,j is not a straight line but may meander essentially parallel to the horizontal component of the flow direction {right arrow over (d)}h.
Alternatively, the boundary Bi,j may meander orthogonal to the horizontal component of the flow direction {right arrow over (d)}h. In this case the relation |{right arrow over (d)}o·({right arrow over (b)}i,j,l−{right arrow over (b)}i,j,e)|≠|{right arrow over (d)}o·({right arrow over (b)}i,j,m−{right arrow over (q)}e)|∀{right arrow over (b)}i,j,l,{right arrow over (b)}i,j,m∈Bi,{right arrow over (b)}i,j,l≠{right arrow over (b)}i,j,m, wherein {right arrow over (d)}o⊥{right arrow over (d)}h is obeyed, while condition |{right arrow over (d)}h·({right arrow over (b)}i,j,l−{right arrow over (b)}i,j,e)|≠|{right arrow over (d)}h·({right arrow over (b)}i,j,m−{right arrow over (q)}e)|∀{right arrow over (b)}i,j,l,{right arrow over (b)}i,j,m∈Bi,{right arrow over (b)}i,j,l≠{right arrow over (b)}i,j,m (condition 13.1) may preferably not be realized.
These measures being referenced to as conditions 13.1 and 13.2 each vastly simplify to coordinate the movement of the n beam spots over the layer such that at any moment in time no beam spot is below fume that has been generated by another beam spot, while operating the beam sources simultaneously.
As stated above, the beam sources may be pivoted while irradiating the surface to thereby project beam spots onto the layer. Thus, preferably each beam spot may be moved over the surface of the layer and thereby fuses the fusible material at the locations {right arrow over (l)}i of the respective set of locations Li. In other words, fusing the fusable material at the set of locations Li includes pivoting the ith beam source while the ith-beam source projects the ith-beam onto the area A to thereby move the ith-beam spot. Preferably the movement of the ith-beam spot can be described by a multiple of a vector {right arrow over (v)}i having a component being opposite to the flow direction {right arrow over (d)}h of the inert gas flow. The beam spot so to speak moves towards the gas inlet and hence the fusing process is less affected by fumes previously produces by said beam spot. Subsequently, the beam source may be switched off and repositioned to continue irradiating another subset of Li while moving again in the direction being defined by {right arrow over (v)}i. The quality of the workpiece to be manufactures is increased accordingly.
For example, there may be at least two different meandering lines Bi,j, Bq,r, which are the boundaries between adjacent sets of locations Li, Lj and Lq, Lr, respectively. Preferably, an end point of the first section Bi,j may as well be an end point of the first section Bq,r. This measure aligns the corresponding sets of locations Li, Lj, Lq and Lr, preferably parallel and orthogonal to the flow direction {right arrow over (d)}h being parallel to the layer. The latter can be obtained when, including the constraint on Si that condition 13.1 or 13.2 applies to both, Bi,j and Bq,r. Thereby the computational effort of the method can be further reduced and idle times to avoid beam spots at locations of fume being produced by other beam spots can be reduced. Thus, the quality of the workpiece can be enhanced while at the same time manufacturing cost for a workpiece are reduced.
For example, if condition 13.1 applies to both, Bi,j and Bq,r, the sets of locations Li, Lj, Lq and Lr, may be separated into m portions Ls,1, Ls,2, . . . , Ls,m,, (m≥2) by lines meandering parallel to {right arrow over (d)}h and wherein |Ls,l|=|Ls,n|±0.15·|Ls,n|∀s∈{i, j, q, r}, l, n≤m, l≠n, (the factor 0.15 can be replaced by any other value of {0.1, 0.05, 0.025, 0.1, 0.005}) wherein portions with the same second index are aligned parallel to {right arrow over (d)}h and in that only portions with the same second index are irradiated simultaneously. This provides for a very effective and simple measure to avoid that fumes being produces by any beam spot affects fusing of the fusible material by another beam spot. An increase of the number of portions enables to increase the minimum distance between two beam spots measured perpendicular to the vector {right arrow over (d)}h. Meandering parallel or orthogonal to {right arrow over (d)}h means that the distance measured parallel, or orthogonal, respectively, to {right arrow over (d)}h between an end point of the respective line and any other point of said line is unique (condition 13.1 or 13.2, respectively, applies to said line).
Preferably, the forming region that has area A may be separated (divided) into at least 2n stripes or sub-regions (generally into c·n stripes, wherein c is an integer with c≥2) extending at least essentially parallel to the horizontal component {right arrow over (d)}h of the inert gas flow. Preferably, during fusing only locations Li in every second stripe are fused at the same time. Thus, in between of two beam spots may be at least a distance corresponding to the width of the corresponding stripe. This results and thus implies a scanning with beam source(s) of at least c·n stripes. By choosing the width of the stripes, one can avoid that any beam spot fuses at a location with a significant concentration of fumes which has been produced by another beam spot. Thus, between two stripes being irradiated or fused simultaneously, there are c−1 stripes which are not irradiated and their width may be the minimum distance by which two beam spots are separated. This allows to initially radiate a first set of the stripes and subsequently a second set of the stripes until the forming region having area A is irradiated. As already apparent, the boundaries of at least some of the stripes are preferably given by the meandering lines as explained above.
Only to avoid any misunderstanding, we recall that as usual the layer is the top layer of a powder bed. Further, herein, as usual “{}” symbolizes an empty set. Herein we use as well the number “0” to express that a set is empty, i.e. if a set V is empty is can be expressed as V={} as well as V=0.
Herein at “least essentially perpendicular” or “least essentially orthogonal” expressed, that an angle of 90° is preferred, but that deviations may be accepted, the angle may thus be within 90°±45°, 90°±30°, 90°±15°, 90°±10°, 90°±5°, 90°±2.5°, 90°±1° or 90°±0°. Similarly, “least essentially parallel” allows for deviations from perfect parallel alignment, i.e. angles be within 0°±45°, 0°±30°, 0°±15°, 0°±10°, 0°±5°, 0°±2.5°,° ±1° or 0°±0° may be selected as well, wherein exactly parallel) (±0°) is preferred. Further, two meandering lines meandering in the directions being given by vectors {right arrow over (b)}1 and {right arrow over (b)}2 are considered to be perpendicular or parallel, if these vectors {right arrow over (b)}1 and {right arrow over (b)}2 are perpendicular or parallel, respectively.
In the following, the invention will be described by way of example, without limitation of the general inventive concept, on examples of embodiment and with reference to the drawings.
Generally, the drawings are not to scale. Like elements and components are referred to by like labels and numerals. For the simplicity of illustrations, not all elements and components depicted and labeled in one drawing are necessarily labels in another drawing even if these elements and components appear in such other drawing.
While various modifications and alternative forms, of implementation of the idea of the invention are within the scope of the invention, specific embodiments thereof are shown by way of example in the drawings and are described below in detail. It should be understood, however, that the drawings and related detailed description are not intended to limit the implementation of the idea of the invention to the particular form disclosed in this application, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
In
The surface 14 of the powder bed in
During fusing of the powder bed's surface 14 fumes occur at the locations {right arrow over (l)}i of the surface. These fumes may be removed from the process chamber by establishing an inert gas flow 3 above and over the surface 14 of the powder bed 12 being symbolized by dashed arrows 3. The dashed arrows 3 each have common projection on the bottom 8, being symbolized the dotted arrow {right arrow over (d)}h. The vector {right arrow over (d)}h is thus the direction of the horizontal component of the inert gas flow 3 above and over the surface 14. In other words, the inert gas flow 3 has a component {right arrow over (d)}h being parallel to the support's up facing surface.
A programmable electronic circuitry 10, briefly referred to as controller 10, controls at least a number of the beam sources 20i. Preferably as well at least one of the inert gas flow 3, a recoater and the movement of the support 82 may be controlled by the controller 10.
Each beam source20i can irradiate a certain portion Fi of the surface 14. These surfaces F1, . . . , F14 are referred to as fields of view Fi.
As already explained above, the beam sources are labelled with indices or in any other appropriate manner, that enables to distinguish two of them. Herein we assume that the sets of locations Li to be irradiated by the ith-beam source 20i are determined in an ascending order, starting with the first beam source 201. This ascending order is not required, but simplifies to explain and understand the invention. Accordingly, the last set of locations L14 is already defined if all other 13 sets have been determined, as it is the not yet assigned portion of the area A to be fused, i.e. L14=A−Σi=113Li or for any number n of beam sources Ln=A−Σi=1n−1Li.
Once the beam sources 20i are labelled and the area A to be irradiated has been determined intersecting sets ISi of the fields of view Fi with the area A may be determined, generally ISi=Fi∩A, as depicted in
Preferably, the actual fusing times tα(i) are all the same and in this case the optimum fusing time of the first beam source can be estimated as to(1)=|A|/Σi=1nRi, wherein the values Ri are the fusing rate of the ith-beam source (see
This example of determining to(1) is not the only valid choice for to(i). Generally any value of to(i) being withing
may be considered reasonable, generally
can be considered as a reasonable range for the margin, e.g. βt,i∈B, with B={0.25, 0.2, 0.15, 0.1, 0.05, 0.025, 0.0125, 0.01, 0.005, 0.001}. Smaller values of βt,i are preferred, particularly preferred may be βt,i=0.
If to(1) has been determined, the method may proceed to determining the first subtrahend surface S1 (see
There may be cases in which the constraint (1−α1)·(|IS1|−to(1)·R1)≤|S1|≤(1+α1)·(|IS1|−to(1)·R1) cannot be met, because the size of IS1 may be smaller than (1−α1)·to(1)·R1 (see
As already explained above, it is preferred if the sets of locations Li have a size above a threshold Ti i.e. if |Li|>Ti. If this condition cannot be met, Si may be set to ISi, i.e. Si:=ISi being equivalent to removing the ith beam source from the pool of available beam sources.
Subsequently, these steps may be repeated for the next beam source, which in this example may be the second beam source. Formally this can be described as repeating the steps after replacing the index 1 by 2 and by using to(2) instead of to(1) (see
more generally and to allow small deviations from the suggested optimum value one may determine the updated optimum time to obey the constraint
being equivalent to
or in short
wherein if i=0 the term Σj=1i−1|Lj|:=0 and hence
Again, the preferred case may be βt,i=0.
Next or as well prior to determining the updated optimum fusing time to(i) the next intersecting set may be determined using ISi:=Fi∩A.
Once ISi and to(i) are determined, the method may proceed to the step of determining the corresponding subtrahend surface Si, wherein Si obey the condition ∀{right arrow over (p)}1∈S1, ∃Fk|{right arrow over (p)}1∈Fk, k>i and if |ISi|≥to(i)·RiSi further obeys (1−αi)·(|ISi|−to(i)·Ri)≤|Si|≤(1−αi)·(|ISi|−to(i)·Ri), and αi∈{0.25, 0.2, 0.15, 0.1, 0.05, 0.025, 0.01, 0.005, 0}.
Once the ISi and Si are determined, the method may proceed to define Li:=ISi−Si, and to increase i by one (i:=i+1, unless i=n) and reiterate the process until n sets of locations Li, 1≤i≤n have been determined. As already apparent, the nth set can as well be determined using Ln=A−Σi=1n−1Li. The controller may then control the beam sources 20i to project their respective beam spots 22i onto the corresponding sets of locations Li.
An example for determining a subtrahend surface Si is explained with respect to
In the example of
When determining the subtrahend surface S1 (more generally Si) one may simply shift the meandering lines B1,j and B1,k (more generally Bi,j and Bi,k). In a preferred example embodiment, the corresponding meandering lines Bi,j and Bi,k may be shifted at least essentially perpendicularly (i.e. within 90°±45°, ±30°, ±15°, ±10°, ±5°, ±2.5°, ±1° or ±0°) to their respective vectors {right arrow over (b)}1 and {right arrow over (b)}2 until the conditions for S1 (more generally Si) are obeyed. In other words, the lines Bi,j and Bi,k may define inner boundaries of the subtrahend surface Si, while the outer boundary may be provided by the boundary of the corresponding field of view Fi, or preferably by the outer boundary of ISi, wherein the terms “inner” and “outer” reference to the location being defined by the centre of the field of view Fi of the respective ith beam source, being herein denoted by an “x” representing the corresponding projection of the ith-beam source.
In the example of
If the geometry and/or the location of the area A relative to an ith-beam sources field of view Fi is different, then three or four of the meandering lines may be required to determine the inner boundary of the subtrahend surface.
A corresponding example is shown in
The method may next proceed with determining the next subtrahend surface Si+1 (in the given example with S11+1=S12).
The example method can be implemented particularly easy, if the sequence of determining the subtrahend surfaces Si may be selected based on the ability of the ith-beam source to contribute to fusing the area A. A measure for this ability to contribute can be considered as the size of the overlap of their respective fields of view Fi with the area A. Thus, as can be seen immediately, in the example of
It will be appreciated to those skilled in the art having the benefit of this disclosure that this invention is believed to provide a method for manufacturing a workpiece, a storage medium including a program and an additive manufacturing apparatus. Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is provided for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as the presently preferred embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the spirit and scope of the invention as described in the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2021 110 091.7 | Apr 2021 | DE | national |
This US Patent Application is a continuation of the pending U.S. patent application Ser. No. 18/489,164 filed on Oct. 18, 2023 and now published as US 2024/0246150, which is a continuation of the International Patent Application No. PCT/EP2022/059930 filed on Apr. 13, 2022 and now published as WO 2022/223411, which designates the United States and claims priority from the German Patent Application No. DE 10 2021 110 091.7 filed on Apr. 21, 2021. The disclosure of each of the above-identified patent documents is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18489164 | Oct 2023 | US |
| Child | 19085280 | US | |
| Parent | PCT/EP2022/059930 | Apr 2022 | WO |
| Child | 18489164 | US |
