WO2008074287A1 - Method for the production of a three-dimensional component - Google Patents

Method for the production of a three-dimensional component Download PDF

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Publication number
WO2008074287A1
WO2008074287A1 PCT/DE2007/002092 DE2007002092W WO2008074287A1 WO 2008074287 A1 WO2008074287 A1 WO 2008074287A1 DE 2007002092 W DE2007002092 W DE 2007002092W WO 2008074287 A1 WO2008074287 A1 WO 2008074287A1
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Prior art keywords
individual
individual sections
section
component
irradiation
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PCT/DE2007/002092
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German (de)
French (fr)
Inventor
Frank Herzog
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Cl Schutzrechtsverwaltungs Gmbh
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Publication of WO2008074287A1 publication Critical patent/WO2008074287A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/36—Process control of energy beam parameters
    • B22F10/366—Scanning parameters, e.g. hatch distance or scanning strategy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to a method for producing a three-dimensional component, in particular a laser sintering or laser melting method for use in a laser sintering machine, in which the component is produced by successive solidification of individual layers of solidifiable building material by the action of radiation, in particular laser radiation, wherein the point - And / or preferably linear energy input in at least one layer in flat individual sections.
  • the invention has for its object to form a method with the features of claim 1 such that occur in the solidification of the individual layers of the lowest possible voltages within a component layer. It is another object of the invention to define the individual sections and the irradiation sequence such that they generate only small voltages depending on the component geometry during manufacture. Furthermore, a simple and fast construction process should be made possible. This object is solved by the characterizing features of claim 1, advantageous developments of the invention will become apparent from the dependent claims October 16, 2007 Ha / 20070300
  • the irradiation order at least partially so runs that after a point or line energy input within a first single section of the following energy input in a second second single section and the subsequent energy input either in a third or an already partially irradiated single section takes place, wherein the successively irradiated individual sections and / or performed energy entries are not immediately adjacent.
  • the use of flat individual sections that is to say individual sections which have a defined length in both the X and Y directions, enable a more targeted and at the same time less stressful introduction of energy into a component layer.
  • the distance of at least two successively irradiated individual sections corresponds to at least the smallest cross section of a single section or the distance corresponds to at least two energy inputs at least the smallest cross section of an energy input.
  • a further advantageous measure is the irradiation order of the individual sections and / or the energy entries after a stochastic one October 16, 2007 Ha / 20070300
  • the stochastic selection of the order of irradiation is limited to the effect that no two successive energy entries lie directly next to one another.
  • the stochastic distribution ensures a uniform energy input to the individual layers of the component.
  • the stability, in particular the bending stiffness, of a component consisting of individual square sections arranged in the manner of a chess board on the individual layers of the component can be increased by alternately arranging the irradiation lines in the first single section in a first direction and in a subsequent single section are irradiated in a direction perpendicular to the first.
  • alignment angles deviating from 90 ° relative to a first energy input may also be advantageous, for example a 60 ° deviation of the orientation of the irradiation lines in the case of a hexagonal single-section structure.
  • the shape of at least one individual section is square, furthermore, the individual section shapes can also be rectangular or hexagonal.
  • the shape and / or dimensioning of at least two individual sections need not necessarily be identical, so it is advantageous, for example, to arrange square and rectangular individual sections within a component layer and thus to achieve a higher component stability by generating by means of an offset.
  • Component can be achieved and thus the overall stability of the component area-dependent positively influenced.
  • edge regions of the individual sections are irradiated as a grid structure separately and / or by overlapping a plurality of individual sections.
  • Such a lattice structure can be aligned both parallel to the layers of the component, but also extend perpendicularly or at other angles to them over a plurality of component layers.
  • the solidification of the grid lines can take place as a final irradiation measure within a layer, for example with a grouping of defined individual sections.
  • two single-segment groupings can be distributed in a component layer in the manner of a checkerboard (black and white fields) and "usually” irradiate them.
  • a third single-segment grouping is used to selectively target specific areas within a component layer, for example Another example is to irradiate a first region of a component, which is slightly stressed in the operating state of the component, with two individual segment groups whose individual section shape is quadratic on the one hand and whose edges do not overlap and within one another the same Bauteilscbicht in a second, in the operating state of the component highly loaded area of the component this with October 16, 2007 Ha / 20070300
  • Fig. 1 is a schematic representation of a subdivided into individual sections
  • FIG. 2 shows a schematic representation according to FIG. 1 with an irradiation order according to the invention
  • FIG. 3 shows a schematic illustration according to FIG. 1 with an alternative irradiation sequence according to the invention
  • FIG. 4 is a schematic representation of a component layer which is irradiated by individual sections of different geometries
  • Fig. 5 is a schematic representation of a device layer with different Einzelabitessgrupptechniken.
  • drawing figure 1 is a known from the prior art method for
  • the component 1 is produced by sequential solidification of individual layers 2 of solidifiable building material by the action of a radiation, in particular a laser radiation.
  • the energy input 3 is in line form and does not extend continuously over the entire component length, but is distributed in flat individual sections 4 on the component 1.
  • the individual sections 4 are provided with capital letters A, B, C,... Within the individual sections 4, the linear energy inputs 3 are shown with a small arrow 5 which shows the direction of travel of the laser beam. All energy entries 3 are provided with lowercase letters a, b, c, ..., indicating the order of irradiation.
  • drawing figure 1 it can be seen from drawing figure 1 that, as the first in individual section 4A, it is completely irradiated with the energy inputs 3a-3e.
  • the single section 4F is irradiated with the energy inputs 3f-3j and subsequently the single section 4G is started.
  • the individual successive energy inputs 3 and the individual successively completely irradiated individual sections 4 are spaced from one another.
  • the irradiation sequence takes place within a construction process at least in regions such that after a first point or line energy input 3 within a first single section 4 of the following energy input 3 in a further second single section 4 and the subsequent energy input 3 either in a third or an area already irradiated section 4, wherein the successively irradiated individual sections 4 and / or performed energy inputs 3 are not immediately adjacent.
  • the first energy input 3a takes place in the individual section 4A, the subsequent second energy entry 3b in the individual section 4C, the third 3c in individual section 4E, etc.
  • the second placed in the single section 4A energy input j takes place only when all individual sections 4 have experienced an energy input 3. Furthermore, it can be seen from the exemplary embodiment that the spacing 6 of at least two individual sections 4A, 4F irradiated in succession corresponds at least to the smallest cross-section 7 of a single section 4F. It can also be seen that the distance 8 of at least two consecutive energy inputs 3 g, 3 h corresponds to at least the smallest cross section 9 of an energy input 3 g.
  • the irradiation order of the individual sections 4 and the energy inputs 3 is determined by a stochastic selection method.
  • the first energy input 3 a takes place in the single section 4A, the second 3b in the single section 4H, the third 3c in the single section 4C, the fourth 3d in the single section 4G, etc.
  • the energy inputs 3 and individual sections 4 irradiated one after the other are spaced apart from one another (compare distances 6, 8).
  • the orientation of the linear energy input 3 differs in at least two individual sections 4.
  • the line-shaped energy inputs 3 of the individual sections 4B, 4D, 4F, 4H 5 are parallel to one another, but oriented perpendicular to the further individual sections 4 A, 4 C, 4 E, 4 G, 41.
  • Component 1 the individual sections 3 can include both square, rectangular and hexagonal shapes. To increase the stability of the component
  • Grid structure can be created, which can be generated by separate and / or by overlapping multiple sections 4.
  • the solidification of the grid lines can take place as a final irradiation measure within a layer 2.
  • the embodiment in drawing figure 5 represents a component 1, which has a U-shaped cross-section in the illustrated layer 2.
  • the individual sections 4 are combined in four ⁇ individual section groupings 10.
  • the first Einzelabitessgrupptechnik 10 is formed from the individual sections 4 A - 4F; the second single-segment grouping 10 from the single-section groups 4G-4J; the third of the individual sections K and L and the fourth of the individual sections 4M - 4P.
  • These individual section groupings 10 are irradiated in accordance with the component requirements with a different irradiation sequence, irradiation time, single section form, irradiation intensity and / or different degree of overlap.
  • Such a division of the cross-sectional layer 2 of the component 1 is useful not only in critical component cross-sections, but also in principle in solid components 1, which are divided into an envelope region and a core region, makes sense. Due to the variation of the irradiation sequence, irradiation time, single-section form,
  • Irradiation intensity and / or the degree of overlap of individual section 4 for example, different component densities and / or stabilities within a layer 2 can be realized.

Abstract

The invention relates to a method for the production of a three-dimensional component, particularly a laser sintering or laser melting method, for use in a laser sintering machine, wherein the component is produced by the successive compacting of individual layers made of a structural material that can be compacted by exposure to radiation, particularly to laser radiation, wherein the punctiform and/or linear application of energy occurs in at least one layer in two-dimensional individual sections. The irradiation sequence within a structural process is carried out at least in sections such that after a punctiform or linear application of energy within a first individual section the subsequent application of energy occurs in a further, second individual section, and the subsequent application of energy occurs either in a third or in a (first) individual section that has already been partially irradiated, wherein the successively exposed individual sections and/or completed applications of energy do not lie directly next to each other.

Description

16. Oktober 2007 Ha/20070300 October 16, 2007 Ha / 20070300
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BESCHREIBUNGDESCRIPTION
Verfahren zur Herstellung eines dreidimensionalen BauteilsMethod for producing a three-dimensional component
Die Erfindung betrifft ein Verfahren zum Herstellen eines dreidimensionalen Bauteils, insbesondere ein Lasersinter- oder Laserschmelzverfahren zur Anwendung in einem Lasersinterautomaten, bei dem das Bauteil durch aufeinanderfolgendes Verfestigen einzelner Schichten aus verfestigbarem Baumaterial durch Einwirkung einer Strahlung, insbesondere einer Laserstrahlung, erzeugt wird, wobei der punkt- und/oder vorzugsweise linienförmige Energieeintrag in mindestens einer Schicht in flächigen Einzelabschnitten erfolgt.The invention relates to a method for producing a three-dimensional component, in particular a laser sintering or laser melting method for use in a laser sintering machine, in which the component is produced by successive solidification of individual layers of solidifiable building material by the action of radiation, in particular laser radiation, wherein the point - And / or preferably linear energy input in at least one layer in flat individual sections.
Aus den Patentanmeldungen DE 100 42 134 Al und DE 100 42 132 Al sind Verfahren bekannt, bei welchen ein Bauteil durch aufeinanderfolgendes Verfestigen einzelner Schichten hergestellt wird, wobei der Energieeintrag in flächigen, beispielsweise quadratischen Einzelabschnitten erfolgt. Durch ein derartiges Verfahren wird es erreicht, die Spannungen bei der Verfestigung der einzelnen Schichten zu reduzieren.From the patent applications DE 100 42 134 Al and DE 100 42 132 Al methods are known in which a component is produced by successive solidification of individual layers, wherein the energy input takes place in flat, for example square individual sections. By such a method it is achieved to reduce the stresses in the solidification of the individual layers.
Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren mit den Merkmalen des Anspruches 1 derart auszubilden, daß bei der Verfestigung der einzelnen Schichten möglichst geringe Spannungen innerhalb einer Bauteilschicht auftreten. Ferner ist es Aufgabe der Erfindung, die Einzelabschnitte und die Bestrahlungsabfolge derart zu definieren, daß sie abhängig von der Bauteilgeometrie bei der Herstellung nur geringe Spannungen erzeugen. Des weiteren soll ein einfacher und schneller Bauprozeß ermöglicht werden. Diese Aufgabe wird durch die kennzeichnenden Merkmale des Anspruches 1 gelöst, vorteilhafte Weiterbildungen der Erfindung ergeben sich aus den Unteransprüchen 16. Oktober 2007 Ha/20070300The invention has for its object to form a method with the features of claim 1 such that occur in the solidification of the individual layers of the lowest possible voltages within a component layer. It is another object of the invention to define the individual sections and the irradiation sequence such that they generate only small voltages depending on the component geometry during manufacture. Furthermore, a simple and fast construction process should be made possible. This object is solved by the characterizing features of claim 1, advantageous developments of the invention will become apparent from the dependent claims October 16, 2007 Ha / 20070300
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AIs Kern der Erfindung wird es angesehen, daß innerhalb eines Bauprozesses die Bestrahlungsreihenfolge zumindest bereichsweise derart abläuft, daß nach einem punkt- oder linienförmigen Energieeintrag innerhalb eines ersten Einzelabschnittes der folgende Energieeintrag in einem weiteren zweiten Einzelabschnitt erfolgt und der darauf folgende Energieeintrag entweder in einem dritten oder einem bereits bereichsweise bestrahlten Einzelabschnitt erfolgt, wobei die nacheinander bestrahlten Einzelabschnitte und/oder erfolgten Energieeinträge nicht unmittelbar nebeneinander liegen. Die Verwendung flächiger Einzelabschnitte, also Einzelabschnitte, die sowohl in X- als auch in Y-Richtung eine definierte Länge aufweisen, ermöglichen einen gezielteren und zugleich spannungsärmeren Energieeintrag in eine Bauteilschicht. Da der Energieeintrag nicht zwangsläufig als eine stetige Scanlinie einen Querschnitt des Bauteils überfahrt, kann über die Anordnung der Einzelabschnitte eine gezielte, auf die Bauteilgeometrie oder Bauteileigenschaften abgestimmte Verfestigung des Baumaterials erreicht werden. Insbesondere durch die Bestrahlungsreihenfolge gemäß Anspruch 1 und der Prämisse, daß nacheinander bestrahlten Einzelabschnitte und/oder Energieeinträge nicht unmittelbar nebeneinander liegen, wird erreicht, daß die erzeugten Spannungen auf den einzelnen Bauteilschichten auf einen geringen Bereich begrenzt sind.As A core of the invention, it is considered that within a construction process, the irradiation order at least partially so runs that after a point or line energy input within a first single section of the following energy input in a second second single section and the subsequent energy input either in a third or an already partially irradiated single section takes place, wherein the successively irradiated individual sections and / or performed energy entries are not immediately adjacent. The use of flat individual sections, that is to say individual sections which have a defined length in both the X and Y directions, enable a more targeted and at the same time less stressful introduction of energy into a component layer. Since the energy input does not necessarily pass over a cross-section of the component as a continuous scan line, a specific consolidation of the building material, which is tailored to the component geometry or component properties, can be achieved via the arrangement of the individual sections. In particular, by the order of irradiation according to claim 1 and the premise that successively irradiated individual sections and / or energy inputs are not immediately adjacent, it is achieved that the voltages generated on the individual component layers are limited to a small range.
In vorteilhafter Weise entspricht der Abstand wenigstens zweier nacheinander bestrahlter Einzelabschnitte mindestens dem kleinsten Querschnitt eines Einzelabschnitts bzw. der Abstand wenigstens zwei Energieeinträge mindestens dem kleinsten Querschnitt eines Energieeintrages. Mittels eines solchen Mindestabstandes zweier Einzelabschnitte und/oder Energieeinträge wird gewährleistet, daß sich die eingebrachte Wärmeenergie nicht auf weitere benachbarte verfestigte, sowie nicht verfestigte Bereiche auswirkt.Advantageously, the distance of at least two successively irradiated individual sections corresponds to at least the smallest cross section of a single section or the distance corresponds to at least two energy inputs at least the smallest cross section of an energy input. By means of such a minimum distance between two individual sections and / or energy inputs, it is ensured that the introduced heat energy does not affect further adjacent solidified, as well as non-solidified areas.
Eine weitere vorteilhafte Maßnahme ist es, die Bestrahlungsreihenfolge der Einzelabschnitte und/oder der Energieeinträge nach einem stochastischen 16. Oktober 2007 Ha/20070300A further advantageous measure is the irradiation order of the individual sections and / or the energy entries after a stochastic one October 16, 2007 Ha / 20070300
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Auswahlverfahren erfolgen zu lassen. Gleichzeitig ist jedoch die stochastische Auswahl der Bestrahlungsreihenfolge dahingehend beschränkt, daß keine zwei nacheinander erfolgten Energieeinträge unmittelbar nebeneinander liegen. Insbesondere die stochastische Verteilung gewährleistet einen gleichmäßigen Energieeintrag auf die einzelnen Schichten des Bauteils.Selection procedure. At the same time, however, the stochastic selection of the order of irradiation is limited to the effect that no two successive energy entries lie directly next to one another. In particular, the stochastic distribution ensures a uniform energy input to the individual layers of the component.
Zur Steigerung der Stabilität des Bauteils kann es vorteilhafter Weise vorgesehen sein, die linienförmigen- Energieeinträge in mindestens zwei Einzelabschnitten unterschiedlich auszurichten. Beispielsweise läßt sich die Stabilität, insbesondere die Biegesteifigkeit eines Bauteils, das aus quadratischen Einzelabschnitten, die in Art eines Schachbretts auf den einzelnen Schichten des Bauteils angeordnet sind, dadurch erhöhen, daß die Bestrahlungslinien abwechselnd im ersten Einzelabschnitt in einer ersten Richtung und in einem anschließenden Einzelabschnitt in einer zur ersten senkrechten Ausrichtung bestrahlt werden. Darüber hinaus können auch von 90° abweichende Ausrichtungswinkel bezogen auf einen ersten Energieeintrag vorteilhaft sein, beispielsweise eine 60°- Abweichung der Ausrichtung der Bestrahlungslinien bei einer hexagonalen Einzelabschnittsstruktur.In order to increase the stability of the component, it may be advantageous to align the linear energy inputs in at least two individual sections differently. For example, the stability, in particular the bending stiffness, of a component consisting of individual square sections arranged in the manner of a chess board on the individual layers of the component can be increased by alternately arranging the irradiation lines in the first single section in a first direction and in a subsequent single section are irradiated in a direction perpendicular to the first. In addition, alignment angles deviating from 90 ° relative to a first energy input may also be advantageous, for example a 60 ° deviation of the orientation of the irradiation lines in the case of a hexagonal single-section structure.
In einer vorteilhaften Ausfuhrungsform ist die Form mindestens eines Einzelabschnittes quadratisch, ferner können die Einzelabschnittsformen auch rechteckig oder sechseckig ausgebildet sein. Dabei muß die Form und/oder Dimensionierung mindestens zweier Einzelabschnitte nicht zwangsläufig identisch sein, so ist es beispielsweise vorteilhaft, quadratische und rechteckige Einzelabschnitte innerhalb einer Bauteilschicht anzuordnen und damit durch die Erzeugung mittels eines Versatzes eine höhere Bauteilstabilität zu erreichen.In an advantageous embodiment, the shape of at least one individual section is square, furthermore, the individual section shapes can also be rectangular or hexagonal. In this case, the shape and / or dimensioning of at least two individual sections need not necessarily be identical, so it is advantageous, for example, to arrange square and rectangular individual sections within a component layer and thus to achieve a higher component stability by generating by means of an offset.
Im weiteren wird vorgeschlagen, daß sich mindestens zwei Einzelabschnitte überschneiden, an derartigen Schnittpunkten, -linien oder -bereichen kann durch einen nochmaligen oder mehrfachen Energieeintrag eine höhere Dichte des 16. Oktober 2007 Ha/20070300In addition, it is proposed that at least two individual sections overlap, at such intersections, lines or areas can be by a repeated or multiple energy input, a higher density of October 16, 2007 Ha / 20070300
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Bauteils erreicht werden und damit die Gesamtstabilität des Bauteils bereichsabhängig positiv beeinflußt werden. Insbesondere ist es in diesem Zusammenhang von Vorteil, wenn die Randbereiche der Einzelabschnitte als Gitterstruktur separat und/oder durch Überschneidung mehrerer Einzelabschnitte bestrahlt werden. Eine derartige Gitterstruktur kann sowohl parallel zu den Schichten des Bauteils ausgerichtet sein, aber auch sich senkrecht oder in anderen Winkeln zu diesen über mehrere Bauteilschichten erstrecken. Dabei kann die Verfestigung der Gitterlinien als abschließende Bestrahlungsmaßnahme innerhalb einer Schicht erfolgen, beispielsweise mit einer Gruppierung definierter Einzelabschnitte.Component can be achieved and thus the overall stability of the component area-dependent positively influenced. In particular, it is advantageous in this context if the edge regions of the individual sections are irradiated as a grid structure separately and / or by overlapping a plurality of individual sections. Such a lattice structure can be aligned both parallel to the layers of the component, but also extend perpendicularly or at other angles to them over a plurality of component layers. In this case, the solidification of the grid lines can take place as a final irradiation measure within a layer, for example with a grouping of defined individual sections.
In Weiterbildung der Erfindung ist es vorgesehen, zumindest ein Teil der Einzelabschnitte zu mindestens zwei Einzelabschnittsgruppierungen zusammenzufassen, die sich in ihrer Bestrahlungsabfolge, Bestrahlungszeit, Einzelabschnittsform, Bestrahlungsintensität und/oder Grad der Überschneidung unterscheiden. Solch eine Gruppierung der Einzelabschnitte birgt eine Vielzahl von Vorteilen in sich. So stellt dies eine einfache ökonomische und zugleich zeitsparende Variante dar, um beispielsweise spezifische Dichteerhöhungen innerhalb einer Bauteilschicht einzubringen. So können beispielsweise zwei Einzelabschnittsgruppierungen, wie im obigen Beispiel kurz angerissen, nach Art eines Schachbretts (schwarze und weiße Felder) in einer Bauteilschicht verteilt sein und diese „gewöhnlich" bestrahlen. Eine dritte Einzelabschnittsgruppierung dient nun dazu, gezielt bestimmte Bereiche innerhalb einer Bauteilschicht mit beispielsweise sechseckigen Einzelabschnitten und einer höheren Bestrahlungszeit, die dortigen Bereiche zu verdichten. Ein weiteres Beispiel ist es, einen ersten, im Betriebszustand des Bauteils gering belasteten Bereich eines Bauteils mit zwei Einzelabschnittsgruppierungen zu bestrahlen, deren Einzelabschnittsform einerseits quadratisch ist und deren Ränder sich nicht überschneiden und innerhalb derselben Bauteilscbicht in einem zweiten, im Betriebszustand des Bauteils hoch belasteten Bereich des Bauteils diesen mit 16. Oktober 2007 Ha/20070300In a further development of the invention, it is provided to combine at least a part of the individual sections into at least two individual section groupings which differ in their irradiation sequence, irradiation time, single section form, irradiation intensity and / or degree of overlap. Such a grouping of the individual sections brings with it a multiplicity of advantages. Thus, this represents a simple economic and time-saving variant, for example, to introduce specific density increases within a component layer. Thus, for example, two single-segment groupings, as briefly sketched in the example above, can be distributed in a component layer in the manner of a checkerboard (black and white fields) and "usually" irradiate them.A third single-segment grouping is used to selectively target specific areas within a component layer, for example Another example is to irradiate a first region of a component, which is slightly stressed in the operating state of the component, with two individual segment groups whose individual section shape is quadratic on the one hand and whose edges do not overlap and within one another the same Bauteilscbicht in a second, in the operating state of the component highly loaded area of the component this with October 16, 2007 Ha / 20070300
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sechseckigen Einzelabschnittsformen zu bestrahlen und diese sich randseitig überschneiden zu lassen, so daß eine stabile hexagonale Gitterstruktur in dem zweiten Bereich der Bauteilschicht erzeugt wird. Diese beiden Beispiele zeigen, wie durch das erfindungsgemäße Verfahren eine höhere Stabilität und insbesondere eine bauteilbereichsspezifische Stabilität erreicht werden kann. Ferner kann es vorteilhaft sein, das Bauteil in einen Hüll- und in einen Kernbereich zu unterteilen und diese beiden Bereiche mit unterschiedlichen Einzelabschnittsgruppierungen zu versehen und zu bestrahlen.To irradiate hexagonal single-section shapes and to let this edge overlap, so that a stable hexagonal lattice structure is generated in the second region of the device layer. These two examples show how a higher stability and in particular a component region-specific stability can be achieved by the process according to the invention. Furthermore, it may be advantageous to divide the component into an envelope and a core region and to provide these two regions with different Einzelabschnittsgruppierungen and irradiate.
Die Erfindung ist anhand von Ausführungsbeispielen in den Zeichnungsfiguren näher erläutert. Diese zeigenThe invention is explained in more detail with reference to embodiments in the drawing figures. These show
Fig. 1 eine schematische Darstellung einer in Einzelabschnitten unterteilteFig. 1 is a schematic representation of a subdivided into individual sections
Bauteilschicht nach dem Stand der Technik;Component layer according to the prior art;
Fig. 2 eine schematische Darstellung gemäß Fig. 1 mit einer erfindungsgemäßen Bestrahlungsreihenfolge;FIG. 2 shows a schematic representation according to FIG. 1 with an irradiation order according to the invention; FIG.
Fig. 3 eine schematische Darstellung gemäß Fig. 1 mit einer alternativen erfindungsgemäßen Bestrahlungsabfolge;FIG. 3 shows a schematic illustration according to FIG. 1 with an alternative irradiation sequence according to the invention; FIG.
Fig. 4 eine schematische Darstellung einer Bauteilschicht, welche durch Einzelabschnitte unterschiedlicher Geometrien bestrahlt wird;4 is a schematic representation of a component layer which is irradiated by individual sections of different geometries;
Fig. 5 eine schematische Darstellung einer Bauteilschicht mit unterschiedlichen Einzelabschnittsgruppierungen.Fig. 5 is a schematic representation of a device layer with different Einzelabschnittsgruppierungen.
In Zeichnungsfigur 1 ist ein aus dem Stand der Technik bekanntes Verfahren zumIn drawing figure 1 is a known from the prior art method for
Herstellen eines dreidimensionalen Bauteils 1 in der Draufsicht dargestellt. Insbesondere handelt es sich um ein Lasersinter- oder Laserschmelzverfahren zur 16. Oktober 2007 Ha/20070300Producing a three-dimensional component 1 shown in plan view. In particular, it is a laser sintering or laser melting process for October 16, 2007 Ha / 20070300
- 6 -- 6 -
Anwendung in einem Lasersinterautomaten, bei dem das Bauteil 1 durch aufeinanderfolgendes Verfestigen einzelner Schichten 2 aus verfestigbarem Baumaterial durch Einwirkung einer Strahlung, insbesondere einer Laserstrahlung erzeugt wird. Dabei erfolgt der Energieeintrag 3 in Linienform und erstreckt sich nicht stetig über die gesamte Bauteillänge, sondern ist in flächige Einzelabschnitte 4 über das Bauteil 1 verteilt.Application in a laser sintering machine, in which the component 1 is produced by sequential solidification of individual layers 2 of solidifiable building material by the action of a radiation, in particular a laser radiation. In this case, the energy input 3 is in line form and does not extend continuously over the entire component length, but is distributed in flat individual sections 4 on the component 1.
Die Einzelabschnitte 4 sind mit den Großbuchstaben A, B, C, ... versehen, innerhalb der Einzelabschnitte 4 sind die linienförmigen Energieeinträge 3 mit einem kleinen Pfeil 5, der die Verfahrrichtung des Laserstrahls zeigt, dargestellt. Sämtliche Energieeinträge 3 sind mit Kleinbuchstaben a, b, c, ... versehen, die die Reihenfolge der Bestrahlung angeben. So ist aus Zeichnungsfigur 1 entnehmbar, daß als erstes im Einzelabschnitt 4A dieser vollständig mit den Energieeinträgen 3a — 3e bestrahlt wird. Anschließend wird der Einzelabschnitt 4F mit den Energieeinträgen 3f - 3j bestrahlt und nachfolgend wird mit dem Einzelabschnitt 4G begonnen. Dabei sind die einzelnen nacheinander erfolgenden Energieeinträge 3, sowie die einzelnen nacheinander vollständig bestrahlten Einzelabschnitte 4 voneinander beabstandet.The individual sections 4 are provided with capital letters A, B, C,... Within the individual sections 4, the linear energy inputs 3 are shown with a small arrow 5 which shows the direction of travel of the laser beam. All energy entries 3 are provided with lowercase letters a, b, c, ..., indicating the order of irradiation. Thus, it can be seen from drawing figure 1 that, as the first in individual section 4A, it is completely irradiated with the energy inputs 3a-3e. Subsequently, the single section 4F is irradiated with the energy inputs 3f-3j and subsequently the single section 4G is started. In this case, the individual successive energy inputs 3 and the individual successively completely irradiated individual sections 4 are spaced from one another.
Bei dem erfindungsgemäßen Verfahren erfolgt die Bestrahlungsreihenfolge innerhalb eines Bauprozesses zumindest bereichsweise derart, daß nach einem ersten punkt- oder linienförmigen Energieeintrag 3 innerhalb eines ersten Einzelabschnittes 4 der folgende Energieeintrag 3 in einem weiteren zweiten Einzelabschnitt 4 erfolgt und der darauf folgende Energieeintrag 3 entweder in einem dritten oder einem bereits bereichsweise bestrahlten Einzelabschnitt 4 erfolgt, wobei die nacheinander bestrahlten Einzelabschnitte 4 und/oder erfolgten Energieeinträge 3 nicht unmittelbar nebeneinander liegen. Dies geht beispielsweise aus Zeichnungsfigur 2 hervor, so findet der erste Energieeintrag 3 a im Einzelabschnitt 4A statt, der darauffolgende zweite Energieeintrag 3b im Einzelabschnitt 4C, der dritte 3c in Einzelabschnitt 4E usw.. In dem in 16. Oktober 2007 Ha/20070300In the method according to the invention, the irradiation sequence takes place within a construction process at least in regions such that after a first point or line energy input 3 within a first single section 4 of the following energy input 3 in a further second single section 4 and the subsequent energy input 3 either in a third or an area already irradiated section 4, wherein the successively irradiated individual sections 4 and / or performed energy inputs 3 are not immediately adjacent. This is apparent, for example, from FIG. 2, the first energy input 3a takes place in the individual section 4A, the subsequent second energy entry 3b in the individual section 4C, the third 3c in individual section 4E, etc. In the in October 16, 2007 Ha / 20070300
- 7 -- 7 -
Zeichnungsfigur 2 dargestellten Ausfuhrungsbeispiel findet der zweite im Einzelabschnitt 4A plazierte Energieeintrag j erst dann statt, wenn sämtliche Einzelabschnitte 4 einen Energieeintrag 3 erfahren haben. Weiter geht aus dem Ausführungsbeispiel hervor, daß der Abstand 6 wenigstens zweier nacheinander bestrahlter Einzelabschnitte 4A, 4F mindestens dem kleinsten Querschnitt 7 eines Einzelabschnitts 4F entspricht. Ferner ist erkennbar, daß der Abstand 8 wenigstens zweier aufeinander folgender Energieeinträge 3 g, 3h mindestens dem kleinsten Querschnitt 9 eines Energieeintrages 3 g entspricht.Drawing 2 illustrated embodiment, the second placed in the single section 4A energy input j takes place only when all individual sections 4 have experienced an energy input 3. Furthermore, it can be seen from the exemplary embodiment that the spacing 6 of at least two individual sections 4A, 4F irradiated in succession corresponds at least to the smallest cross-section 7 of a single section 4F. It can also be seen that the distance 8 of at least two consecutive energy inputs 3 g, 3 h corresponds to at least the smallest cross section 9 of an energy input 3 g.
In einem weiterführenden Ausführungsbeispiels gemäß Zeichnungsfigur 3 ist die Bestrahlungsreihenfolge der Einzelabschnitte 4 und der Energieeinträge 3 nach einem stochastischen Auswahlverfahren bestimmt. Der erste Energieeintrag 3 a findet im Einzelabschnitt 4A, der zweite 3b im Einzelabschnitt 4H, der dritte 3c im Einzelabschnitt 4C, der vierte 3d im Einzelabschnitt 4G, usw. statt. Trotz des stochastischen Auswahlverfahrens sind die nacheinander bestrahlten Energieeinträge 3 und Einzelabschnitte 4 voneinander beabstandet (vgl. Abstände 6, 8). Neben dem stochastischen Auswahlverfahren geht aus dem Ausführungsbeispiel hervor, daß sich die Ausrichtung des linienförmigen Energieeintrages 3 in mindestens zwei Einzelabschnitten 4 unterscheidet. So sind die linienförmigen Energieeinträge 3 der Einzelabschnitte 4B, 4D, 4F, 4H5 zueinander parallel, jedoch in auf die weiteren Einzelabschnitte 4 A, 4C, 4E, 4G, 41 senkrecht stehend ausgerichtet.In a further embodiment according to drawing figure 3, the irradiation order of the individual sections 4 and the energy inputs 3 is determined by a stochastic selection method. The first energy input 3 a takes place in the single section 4A, the second 3b in the single section 4H, the third 3c in the single section 4C, the fourth 3d in the single section 4G, etc. Despite the stochastic selection process, the energy inputs 3 and individual sections 4 irradiated one after the other are spaced apart from one another (compare distances 6, 8). In addition to the stochastic selection process, it can be seen from the exemplary embodiment that the orientation of the linear energy input 3 differs in at least two individual sections 4. Thus, the line-shaped energy inputs 3 of the individual sections 4B, 4D, 4F, 4H 5 are parallel to one another, but oriented perpendicular to the further individual sections 4 A, 4 C, 4 E, 4 G, 41.
Daß die Form der Einzelabschnitte 4 nicht zwangsläufig quadratisch definiert sein muß, geht aus Zeichnungsfigur 4 hervor, wonach innerhalb einer Schicht 2 einesThat the shape of the individual sections 4 need not necessarily be defined quadratically, it is apparent from drawing Figure 4, which within a layer 2 of a
Bauteils 1 die Einzelabschnitte 3 sowohl quadratische, rechteckige wie auch sechseckige Formen umfassen können. Zur Steigerung der Stabilität des BauteilsComponent 1, the individual sections 3 can include both square, rectangular and hexagonal shapes. To increase the stability of the component
1 kann es vorgesehen sein, die Bestrahlung derart zu gestalten, daß sich mindestens zwei Einzelabschnitte 4 überschneiden (nicht dargestellt). Ferner kann durch die Bestrahlung der Randbereiche der Einzelabschnitte 4 eine bauteilinterne 16. Oktober 2007 Ha/200703001 it can be provided to design the irradiation such that at least two individual sections 4 overlap (not shown). Furthermore, by the irradiation of the edge regions of the individual sections 4, a component-internal October 16, 2007 Ha / 20070300
- 8 -- 8th -
Gitterstruktur geschaffen werden, die durch separate und/oder durch Überschneidung mehrerer Einzelabschnitte 4 erzeugt werden kann. Beispielsweise kann die Verfestigung der Gitterlinien als abschließende Bestrahlungsmaßnahme innerhalb einer Schicht 2 erfolgen.Grid structure can be created, which can be generated by separate and / or by overlapping multiple sections 4. For example, the solidification of the grid lines can take place as a final irradiation measure within a layer 2.
Das Ausführungsbeispiel in Zeichnungsfigur 5 stellt ein Bauteil 1 dar, das in der dargestellten Schicht 2 einen u-förmigen Querschnitt aufweist. Die Einzelabschnitte 4 sind in vier ■ Einzelabschnittsgruppierungen 10 zusammengefaßt. Die erste Einzelabschnittsgruppierung 10 wird aus den Einzelabschnitten 4 A — 4F gebildet; die zweite Einzelabschnittsgruppierung 10 aus den Einzelabschnittsgruppen 4G — 4J; die dritte aus den Einzelabschnitten K und L und die vierte aus den Einzelabschnitten 4M - 4P. Diese Einzelabschnittsgruppierungen 10 sind entsprechend der Bauteilanforderungen mit einer unterschiedlichen Bestrahlungsabfolge, Bestrahlungszeit, Einzelabschnittsform, Bestrahlungsintensität und/oder unterschiedlichem Grad der Überschneidung bestrahlt. Eine derartige Aufteilung der Querschnittsschicht 2 des Bauteils 1 ist nicht nur bei kritischen Bauteilquerschnitten sinnvoll, sondern auch grundsätzlich bei massiven Bauteilen 1, die in einen Hüllbereich und einen Kernbereich unterteilbar sind, sinnvoll. Durch die Variation der Bestrahlungsabfolge, Bestrahlungszeit, Einzelabschnittsform,The embodiment in drawing figure 5 represents a component 1, which has a U-shaped cross-section in the illustrated layer 2. The individual sections 4 are combined in four ■ individual section groupings 10. The first Einzelabschnittsgruppierung 10 is formed from the individual sections 4 A - 4F; the second single-segment grouping 10 from the single-section groups 4G-4J; the third of the individual sections K and L and the fourth of the individual sections 4M - 4P. These individual section groupings 10 are irradiated in accordance with the component requirements with a different irradiation sequence, irradiation time, single section form, irradiation intensity and / or different degree of overlap. Such a division of the cross-sectional layer 2 of the component 1 is useful not only in critical component cross-sections, but also in principle in solid components 1, which are divided into an envelope region and a core region, makes sense. Due to the variation of the irradiation sequence, irradiation time, single-section form,
Bestrahlungsintensität und/oder dem Maß der Überschneidung von Einzelabschnitt 4 lassen sich beispielsweise unterschiedliche Bauteildichten und/oder Stabilitäten innerhalb einer Schicht 2 realisieren. Irradiation intensity and / or the degree of overlap of individual section 4, for example, different component densities and / or stabilities within a layer 2 can be realized.
16 Oktober 2007 Ha/2007030016 October 2007 Ha / 20070300
- 9 -- 9 -
BEZUGSZEICHENLISTELIST OF REFERENCE NUMBERS
1 Bauteil1 component
2 Schicht2 layer
3 Energieeintrag3 energy input
4 Einzelabschnitt4 single section
5 Pfeil5 arrow
6 Abstand von 46 distance from 4
7 kleinster Querschnitt von 47 smallest cross section of 4
8 Abstand von 38 distance from 3
9 kleinster Querschnitt von 39 smallest cross section of 3
10 Einzelabschnittsgruppierung10 single-segment grouping
A5 B5 ... Einzelabschnitte a, b5 ... Bestrahlungsfolge der Energieeinträge A 5 B 5 ... Individual sections a, b 5 ... Irradiation sequence of energy inputs

Claims

16. Oktober 2007 Ha/20070300- 10 -PATENTANSPRÜCHE October 16, 2007 Ha / 20070300-10 -PATENTIAL CLAIMS
1. Verfahren zum Herstellen eines dreidimensionalen Bauteils, insbesondere Lasersinter- oder Laserschmelzverfahren zur Anwendung in einem1. A method for producing a three-dimensional component, in particular laser sintering or laser melting method for use in a
Lasersinterautomaten, bei dem das Bauteil durch aufeinanderfolgendesLasersinterautomaten, in which the component by successive
Verfestigen einzelner Schichten aus verfestigbarem Baumaterial durchSolidifying individual layers of solidifiable building material
Einwirkung einer Strahlung, insbesondere einer Laserstrahlung, erzeugt wird, wobei der punkt- und/oder linienförmige Energieeintrag in mindestens einer Schicht in flächigen Einzelabschnitten erfolgt,The action of a radiation, in particular a laser radiation, is generated, wherein the point and / or line energy input takes place in at least one layer in flat individual sections,
dadurch gekennzeichnet, daßcharacterized in that
innerhalb eines Bauprozesses die Bestrahlungsreihenfolge zumindest bereichsweise derart abläuft, daß nach einem ersten punkt- oder linienförmigen Energieeintrag innerhalb eines ersten Einzelabschnitts der folgende Energieeintrag in einem weiteren zweiten Einzelabschnitt erfolgt und der darauffolgende Energieeintrag entweder in einem dritten oder einem bereits bereichsweise bestrahlten (ersten) Einzelabschnitt erfolgt, wobei die nacheinander bestrahlten Einzelabschnitte und/oder erfolgtenWithin a construction process, the irradiation sequence proceeds at least in regions such that following a first point or line energy input within a first individual section, the following energy input occurs in a further second individual section and the subsequent energy input takes place either in a third (or first section) irradiated area , wherein the successively irradiated individual sections and / or done
Energieeinträge nicht unmittelbar nebeneinander liegen.Energy entries are not immediately adjacent.
2. Verfahren nach Anspruch 1 ,2. The method according to claim 1,
dadurch gekennzeichnet, daßcharacterized in that
der Abstand wenigstens zweier nacheinander bestrahlter Einzelabschnitte mindestens dem kleinsten Querschnitt eines Einzelabschnitts entspricht. the distance between at least two successive irradiated individual sections corresponds to at least the smallest cross section of a single section.
16. Oktober 2007 Ha/20070300October 16, 2007 Ha / 20070300
- 11 -- 11 -
3. Verfahren nach Anspruch 1 oder 2,3. The method according to claim 1 or 2,
dadurch gekennzeichnet, daßcharacterized in that
der Abstand wenigstens zweier nacheinander erfolgender Energieeinträge mindestens dem. kleinsten Querschnitt eines Energieeintrages entspricht.the distance of at least two successive energy entries at least the. smallest cross-section corresponds to an energy input.
4. Verfahren nach einem der Ansprüche 1 - 3,4. The method according to any one of claims 1 - 3,
dadurch gekennzeichnet, daßcharacterized in that
die Bestrahlungsreihenfolge der Einzelabschnitte und/oder der Energieeinträge nach einem stochastischen Auswahlverfahren erfolgt.the order of irradiation of the individual sections and / or the energy entries is carried out according to a stochastic selection method.
5. Verfahren nach einem der vorhergehenden Ansprüche,5. Method according to one of the preceding claims,
dadurch gekennzeichnet, daßcharacterized in that
sich die Ausrichtung des linienförmigen Energieeintrags in mindestens zwei Einzelabschnitten unterscheidet.the orientation of the linear energy input differs in at least two individual sections.
6. Verfahren nach einem der vorhergehenden Ansprüche,6. The method according to any one of the preceding claims,
dadurch gekennzeichnet, daßcharacterized in that
die Form mindestens eines Einzelabschnitts quadratisch, rechteckig oder sechseckig ist. the shape of at least one single section is square, rectangular or hexagonal.
16. Oktober 2007 Ha/20070300October 16, 2007 Ha / 20070300
- 12 -- 12 -
7. Verfahren nach einem der vorhergehenden Ansprüche,7. The method according to any one of the preceding claims,
dadurch gekennzeichnet, daßcharacterized in that
die Form und/oder Dimensionierung mindestens zweier Einzelabschnitte unterschiedlich ist.the shape and / or dimensioning of at least two individual sections is different.
8. Verfahren nach einem der vorhergehenden Ansprüche,8. The method according to any one of the preceding claims,
dadurch gekennzeichnet, daßcharacterized in that
sich mindestens zwei Einzelabschnitte überschneiden.at least two individual sections overlap.
9. Verfahren nach einem der vorhergehenden Ansprüche,9. The method according to any one of the preceding claims,
dadurch gekennzeichnet, daßcharacterized in that
die Randbereiche der Einzelabschnitte als Gitterstruktur separat und/oder durch Überschneidung mehrerer Einzelabschnitte bestrahlt werden.the edge regions of the individual sections are irradiated as a grid structure separately and / or by overlapping a plurality of individual sections.
10. Verfahren nach einem der vorhergehenden Ansprüche,10. The method according to any one of the preceding claims,
dadurch gekennzeichnet, daßcharacterized in that
die Verfestigung der Gitterlinien als abschließende Bestrahlungsmaßnahme innerhalb einer Schicht erfolgt. the solidification of the grid lines takes place as a final irradiation measure within a layer.
16. Oktober 2007 Ha/20070300October 16, 2007 Ha / 20070300
- 13 -- 13 -
11. Verfahren nach einem der vorhergehenden Ansprüche,11. The method according to any one of the preceding claims,
dadurch gekennzeichnet, daßcharacterized in that
zumindest ein Teil der Einzelabschnitte zu mindestens zwei Einzelabschnittsgruppierungen zusammengefaßt ist, die sich in ihrer Bestrahlungsabfolge, Bestrahlungszeit, Einzelabschnittsform, BeStrahlungsintensität und/oder Grad der Überschneidung unterscheiden.at least a part of the individual sections is combined to form at least two individual section groupings, which differ in their irradiation sequence, irradiation time, single section form, irradiation intensity and / or degree of overlap.
12. Verfahren nach Anspruch 11 ,12. The method according to claim 11,
dadurch gekennzeichnet, daßcharacterized in that
eine erste Einzelabschnittsgruppierung im wesentlichen im Hüllbereich und eine weitere Einzelabschnittsgruppierung im wesentlichen im Kernbereich eines Bauteils angeordnet ist. a first Einzelabschnittsgruppierung is arranged substantially in the envelope region and a further Einzelabschnittsgruppierung essentially in the core region of a component.
PCT/DE2007/002092 2006-12-15 2007-11-19 Method for the production of a three-dimensional component WO2008074287A1 (en)

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