WO2025202045A1 - Détermination de trajet de balayage dans le processus de fusion de lit de poudre et appareil de fusion de lit de poudre - Google Patents

Détermination de trajet de balayage dans le processus de fusion de lit de poudre et appareil de fusion de lit de poudre

Info

Publication number
WO2025202045A1
WO2025202045A1 PCT/EP2025/057752 EP2025057752W WO2025202045A1 WO 2025202045 A1 WO2025202045 A1 WO 2025202045A1 EP 2025057752 W EP2025057752 W EP 2025057752W WO 2025202045 A1 WO2025202045 A1 WO 2025202045A1
Authority
WO
WIPO (PCT)
Prior art keywords
locations
powder bed
location
sequenced
previous
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2025/057752
Other languages
English (en)
Inventor
Marco STANDFUSS
Maximilian SCHNIEDENHARN
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nikon SLM Solutions AG
Original Assignee
Nikon SLM Solutions AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nikon SLM Solutions AG filed Critical Nikon SLM Solutions AG
Publication of WO2025202045A1 publication Critical patent/WO2025202045A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • 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
    • 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
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/40—Radiation means
    • B22F12/44—Radiation means characterised by the configuration of the radiation means
    • B22F12/45—Two or more
    • 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
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/70—Gas flow means
    • 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
    • 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
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B29C64/264—Arrangements for irradiation
    • B29C64/268—Arrangements for irradiation using laser beams; using electron beams [EB]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—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
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—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
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—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
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • 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

  • a powdered material is selectively fused using thermal energy to manufacture a workpiece.
  • the thermal energy is typically applied to the top layer of a powder bed by scanning an area to be fused with a laser beam or an electron beam.
  • each Lohr, Jöstingmeier & Partner SLM 2024/01 WO Page 2 / 38 21 March 2025 section is scanned by the beam of a separate beam source.
  • An example for a method of dividing an area in sections to be scanned by multiple beams is dis- closed in WO 2022/223411 A, being incorporated herein as if fully disclosed. Scanning the area with multiple beams can reduce the manufacturing time but has disadvantages regarding the quality of the workpiece. For example, the inter- action of the beams with the powder bed leads to the generation of a smoke plume being transported out of the reactor chamber by a gas flow across the powder bed. Scanning a section being covered by a smoke plume is generally possible, but the quality of the workpiece will be reduced.
  • the invention uses these findings to waive or at least reduce the minimum distance between two beam spots (i.e. locations on the powder bed being fused at least essentially simultaneously) be- ing required to ascertain a given quality level.
  • ⁇ identifies a beam source being associated to the section ⁇ ⁇ .
  • a beam source number “ ⁇ ”, i.e. a ⁇ ⁇ beam source may optionally be used later to fuse the section ⁇ ⁇ .
  • the fusing step is not necessarily a part of the invention, as the result of the present method is a scanning path that may be provided to an operator and/or controller of a powder bed fusing apparatus.
  • a location ⁇ ⁇ , ⁇ can be considered as a coordinate on the powder bed that shall be irradiated by a beam (the ⁇ ⁇ -beam) and thereby fused.
  • a beam fuses not only the exact coordinate (having an infinitesimal size) but a surface area that can be identified by the coordinate.
  • a beam Lohr, Jöstingmeier & Partner SLM 2024/01 WO Page 5 / 38 21 March 2025 spot is controlled (e.g. by a controller) to ‘move’ over the surface being defined by all locations ⁇ , ⁇ ⁇ ⁇ and in this sense to scan the set ⁇ of locations ⁇ , ⁇ .
  • the ⁇ -beam source is not necessarily a single beam source, but for conceptionally simplicity it may be assumed herein. Only to provide an example, two beam sources ⁇ ⁇ and ⁇ ! could as well (e.g. al- ternatingly or simultaneously) scan the locations ⁇ ⁇ , ⁇ . In any case, a beam spot moves over the powder bed along a path being defined by a sequence of loca- tions ⁇ ⁇ , ⁇ , the number of beam sources scanning the path does not matter.
  • lo- cations ⁇ ⁇ , ⁇ may even be given only implicitly, e.g., as members of a specified sur- face after the division of the area. It is hence preferred to sequence these loca- tions ⁇ ⁇ , ⁇ in a manner being suited for scanning them by the corresponding beam sources. Sequencing means to rearrange the locations ⁇ ⁇ ⁇ , ⁇ in another sequence being more suited for irradiating them with the ⁇ ⁇ -beam.
  • the two sets of locations ⁇ ⁇ and ⁇ ' ⁇ may hence describe the same surface area and may in this sense be identical, they differ only in the sequence of the locations ⁇ ⁇ , ⁇ and ⁇ ( ⁇ ,) .
  • the sequenced locations ⁇ ( ⁇ ,) are as well vectors; however, the vector symbol has been omitted, i.e. ⁇ ( ⁇ , ⁇ ⁇ ( ⁇ , ⁇ .
  • a sequenced location ⁇ ( ⁇ ,) can be subset of ⁇ , i.e. ⁇ ( ⁇ ,) ⁇ ⁇ .
  • ⁇ ' ⁇ ,) may be a set of multiple ⁇ , ⁇ , and in this case ⁇ *( ⁇ ) ⁇ ⁇ ( ⁇ ).
  • ⁇ ( ⁇ ) ⁇ *( ⁇ )
  • the sequencing defines the sequence in which the locations ⁇ ⁇ , ⁇ may later be irra- diated (e.g. by a beam spot of the ⁇ ⁇ -beam source(s)).
  • the sequencing step defines the sequence in which the lo- cations ⁇ ⁇ , ⁇ are fused.
  • a location ⁇ ⁇ , ⁇ " ⁇ may be assumed to be irradiated by the beam spot immediately after the location ⁇ ⁇ , ⁇ .
  • the locations ⁇ ⁇ , ⁇ and ⁇ ⁇ ⁇ , ⁇ " ⁇ are preferably as well spatial neighbors, and hence a sequence of locations may form a path.
  • “jumps” of the beam spot may be unavoida- ble, but again for conceptional simplicity, it may be assumed herein that loca- tions ⁇ ⁇ , ⁇ and ⁇ ⁇ , ⁇ " ⁇ are neighbors.
  • the sequenced set ⁇ ' ⁇ comprises (preferably: consists) of at least one path of neighbored loca- tions. For example, if a sequenced set ⁇ ' ⁇ has only a single “jump”, i.e. a single ⁇ for which ⁇ ⁇ , ⁇ and ⁇ ⁇ , ⁇ " ⁇ are not neighbors, then the sequenced set ⁇ ' ⁇ consists of two paths.
  • the number of paths is essentially the number of jumps plus one.
  • the spatter of the two beams is ejected predomi- nantly away from the respective other beam (neglecting the effect of the inert gas flow which is neglected only for conceptual simplicity) and hence does not perturb the energy transfer of the respective other beam into the powder parti- cles of the powder bed.
  • a technical effect can already be ob- served if only a subsequence of a single sequenced set ⁇ ' ⁇ is sequenced using the condition, as in this case the 4 ⁇ -beam spot passes over less spatters that have been ejected by scanning the area with the ⁇ ⁇ -beam spot than without se- quencing the single sequenced set ⁇ ' ⁇ accordingly.
  • the relation ⁇ defines a temporal spacing between the points in time when fusing of the locations ⁇ : ⁇ , ⁇ and A 2 is expected and/or scheduled and/or takes place). It is noted that the sequenced locations are as well vectors, although the vector symbol has been omitted ( ⁇ : ⁇ , ⁇ ⁇ : ⁇ , ⁇ ), for simplicity.
  • the sequencing step may comprise dismissing at least one subse- quence that causes the ⁇ ⁇ -beam spot to move away from 4 ⁇ -beam spot that irradiates a location on the powder bed being in the vicinity of the ⁇ ⁇ -beam spot and to replace it by a subsequence that causes the ⁇ ⁇ -beam spot to move (at least essentially) towards ⁇ ⁇ -beam spot.
  • This may be obtained by simply in- verting the subsequence, but other mechanisms for resequencing may be used as well.
  • the sequencing step may comprise concatenating lo- cations ⁇ ⁇ , ⁇ by adding to a given ⁇ ⁇ , ⁇ a vector that has at least a component point- ing towards a location ⁇ 2,) , if the distance between ⁇ ⁇ , ⁇ and ⁇ 2,) is below the Lohr, Jöstingmeier & Partner SLM 2024/01 WO Page 9 / 38 21 March 2025 predefined minimum distance ⁇ ⁇ , ⁇ ,2 and preferably assign to the ⁇ ⁇ ⁇ , ⁇ and ⁇ 2,) an estimated time G( ⁇ ⁇ , ⁇ ) and G( ⁇ 2,) ) for irradiating the respective locations. If the time difference ?GH ⁇ , ⁇ I ⁇ G( ⁇ 2,))?
  • G ⁇ , ⁇ ,2 is greater than a predetermined length of a time interval G ⁇ , ⁇ ,2 (i.e. ?GH ⁇ , ⁇ I ⁇ G( ⁇ 2 ⁇ ,))? > G ⁇ , ⁇ ,2 and/or if the distance be- tween ⁇ ⁇ , ⁇ and ⁇ 2,) is greater than the predefined distance ⁇ ⁇ , ⁇ ,2 , (i.e. ? ⁇ , ⁇ ⁇ ⁇ 2,)? > ⁇ , ⁇ ,2 the sequencing can be performed as known from the prior art. If the two conditions are not met, i.e.
  • a resequencing should be performed, preferably unless other factors like the direction of the inert gas flow and/or heat dissipation and distri- bution in the powder bed favor the existing sequence.
  • Such sequencing then pro- vides a sequenced set ⁇ ' ⁇ of locations which, if used as explained above allows to avoid or at least reduce idle times of beam sources and hence reduces the costs for manufacturing a workpiece of a given quality level.
  • the quality level can be adjusted by choosing ⁇ ⁇ , ⁇ ,2 and G ⁇ , ⁇ ,2 . Further, it may be helpful to further define a minimum separation between the ⁇ ⁇ and 4 ⁇ beam spots.
  • the inven- tion allows to reduce the minimum separation between the ⁇ ⁇ and 4 ⁇ beam spots compared to prior art sequencing mechanisms and thereby to reduce the costs of manufacturing for a given workpiece without compromising the quality of the workpiece.
  • a sequencing strategy has to find a sequence of locations that balances advantages and disadvantages of different, sometimes at least seemingly contradicting conditions.
  • the above explained conditions may hence be waived at least for some subsequences to thereby allow to sequence these subsequences based on more important considerations for these subsequences. Nevertheless, there will be other subsequences for which the suggested condi- tion provides an improvement in workpiece quality and/or manufacturing costs.
  • the number O of subsequences that are sequenced as explained above is preferably greater than the number OP of subsequences that fail to meet the above condition.
  • This scheme may be iterated.
  • the heat distribution to the powder bed is more evenly, Lohr, Jöstingmeier & Partner SLM 2024/01 WO Page 11 / 38 21 March 2025 while the predominant movement of a beam spot ⁇ irradiating said sequence is still in the forward direction and hence towards another beam spot 4 (assuming “forward” as the direction being essentially towards the another beam spot 4 fusing material in the vicinity).
  • a beam spot is moved along a scanning path over the powder bed.
  • the sequence of the locations ⁇ ( ⁇ , ⁇ defining the scanning path of the beam spot is a sequenced set ⁇ ' ⁇ of locations ⁇ ( ⁇ , ⁇ .
  • a beam spot is associated to a location ⁇ ⁇ ⁇ , ⁇ , as it irradiates a location and although not exactly the same, the two terms may be exchanged, because both can be represented by coordinates on the powder bed:
  • a location is a par- ticular surface of the area to be irradiated by a beam spot (or a set of beam spots) being defined by the coordinates ⁇ ⁇ , ⁇ .
  • the surface area of a location is the smallest surface the respective beam source can irradiate, but this is not required. For example, a sequence of such smallest beam spots may be joined into a single location.
  • each sequenced lo- cation ⁇ ( ⁇ ,) may consist of a set of preferably neighbored locations that if a beam spot scans the locations ⁇ , ⁇ ⁇ ⁇ ( ⁇ ,) moves e.g. at least essentially in a forward di- rection, except for a small number of locations ⁇ ⁇ ⁇ , ⁇ .
  • This number of optional ex- ceptional location is preferably smaller or equal than 25% of the number of loca- tions ⁇ ⁇ , ⁇ comprised in the subset ⁇ ( ⁇ ,) .
  • At least one of the sequenced locations ⁇ ' ⁇ com- prises a portion defininig a line segment that extends at least within an error margin of ⁇ ] ⁇ ( ⁇ ] ⁇ ⁇ ⁇ 0°, 1°, 2.5°, 5°, 10°, 15° ⁇ ) parallel to a ⁇ preferential direction ⁇ ⁇ ⁇ , wherein the preferential direction ⁇ ⁇ ⁇ and a horizontal compo- nent ⁇ ⁇ ⁇ of a gas flow direction across the powder bed define an angle ⁇ ⁇ 90° ⁇ ⁇ b with ⁇ b ⁇ ⁇ 0°, 1°, 2°, 5°, 10°, 15° ⁇ , wherein ⁇ b is an error mar- gin.
  • the at least one of the sequenced locations ⁇ ' ⁇ may preferably comprise a sec- ond portion defining a second line segment.
  • each of the two line seg- ments (i.e., of the first line segment and the of the second line segment) has a forward direction and the forward direction of the first line segment is preferably at least essentially antiparallel to the forward direction of the second line Lohr, Jöstingmeier & Partner SLM 2024/01 WO Page 13 / 38 21 March 2025 segment.
  • This measure reduces the time required to fuse a given area, because huge repositioning steps of the beam optics while not irradiating a beam can be avoided.
  • Program instructions for causing a controller to execute any of the method steps herein may be stored on a tangible memory, as well can at least one of the subsequences ⁇ 7 ⁇ , preferably all the subsequences ⁇ 7 ⁇ be stored on a tangible memory. These two memories may be unitary or different entities.
  • the beams may be emitted by lasers. These may have optical sub- systems for shaping (e.g. focusing) the beam and for directing it in a predefined direction, such as lenses (e.g. for focusing) and movable mirrors (e.g.
  • the powder bed fusion process described herein may be executed by an additive manufacturing machine.
  • the additive manufacturing machine may comprise a process chamber.
  • the process chamber may comprise a bed support for the Lohr, Jöstingmeier & Partner SLM 2024/01 WO Page 14 / 38 21 March 2025 powder bed (as well referred to as powder bed support).
  • the bed support may be movable and may be configured to be lowered and raised.
  • the additive manu- facturing machine may further comprise a powder coater.
  • the coater may be configured to apply a layer of powder particles onto the bed support and/or on the top layer of a powder bed on the bed support.
  • the process chamber may be delimited by side walls, e.g. four side walls. At least one side wall of the process chamber may comprise an inert gas inlet. At least one other side wall (e.g.
  • the process chamber may be located in or comprise an enclosure enclosing the side walls and the powder bed support.
  • the additive manufacturing machine may comprise a set of at least two (preferably even more) beam sources configured to selectively fuse particles of the powder bed.
  • a controller of the additive manufacturing machine may be configured to execute the methods described herein.
  • the beam sources may be attached to a beam source support being static (i.e. not movable in the x and/or y direction, assuming the x-y plane to parallel to the powder bed support) relative to the side walls.
  • a second) subset of the beam sources may be attached to a second beam source support.
  • an W ⁇ -subset of the beam sources may be attached to the W ⁇ beam source support.
  • at least one of the beam source supports is movably sup- ported relative to powder bed support. For example, if the powder bed support defines an X-Y plane, the at least one of the beam source supports may be mova- bly at least essentially parallel to the X-Y plane (preferably only).
  • the position of the beam source support may be controlled by a Lohr, Jöstingmeier & Partner SLM 2024/01 WO Page 16 / 38 21 March 2025 controller of the additive manufacturing machine configured to control at least one actuator for driving the beam source support.
  • actuator may be referred to as beam source support drive.
  • the powder bed’s top layer is parallel to the bed support.
  • the at least one of the beam source supports may be movably supported to enable a movement relative to the powder bed. This movement enables to optimize the position of the beam sources, e.g. to reduce effects like defocusing and/or to position the beam sources essentially directly above an area to be irradiated (reducing deflection angles).
  • the additive manufacturing machine may comprise at least one partition.
  • the partition may be a sheet that extends above the powder bed support and/or the powder bed (if present). The partition may separate the distance between the side walls of the process chamber that do not comprise the inert gas inlet or the intert gas outlet in two shorter distances. This reduced distance increases homogeneity of the in- ert gas flow across the powder bed.
  • the inert gas flow is more laminar and thus better predictable. Fumes, spatter etc. being transported by the inert gas flow remain more constrained.
  • the process chamber may comprise more than a single partition.
  • the at least one partition may be sheet metal or any other sheet material that extends preferably at least essentially parallel to the inert gas flow, i.e. a first narrow side of the at least one partition may face towards the inert gas inlet and the opposite narrow side of the at least one partition may face towards the inert gas outlet.
  • the lower Lohr, Jöstingmeier & Partner SLM 2024/01 WO Page 17 / 38 21 March 2025 narrow side of the at least one partition may face towards the bed support and the upper side of the at least one partition may face away from the bed support.
  • the at least one partition may be configured to move parallel (e.g. parallel and synchronously) with and/or to the at least one movable beam source support. This can be accomplished by simply attaching and/or supporting the at least one partition to and/or by the beam source sup- port.
  • the beam source support and the at least one partition may comprise separate drives, but these may be controlled by a controller con- figured to move the two at least essentially parallel to each other.
  • the at least one partition may be logically connected (e.g. by the corre- spondingly configured controller) to the movable beam source support.
  • the powder material mentioned above can be considered as a metal powder and/or a metal alloy powder, however, the invention is not limited in this regard.
  • Thermoplastics, as well referred to as thermosoftening plastic can be used as well.
  • the term fusing shall be understood as a pars pro toto for any mechanism that causes powder particles to adhere after these have been irradiated to the beam spot.
  • the term fusing shall be understood to include at least sintering, welding, brazing, melting, and fusing.
  • a direction being defined to point from a starting point or location essen- tially towards or essentially forward to a given point or location includes any di- rection that, if followed from the starting point at least initially leads to a point or location being closer to the given point or location than the starting point.
  • Figure 1 presents a flow diagram of a method.
  • Figure 2 presents a powder bed with an area to be scanned.
  • Figure 3 presents a detail of Figure 2.
  • Figure 4 presents another detail of a powder bed.
  • Figure 5 presents another detail of a powder bed.
  • Figure 6 presents an additive manufacturing apparatus.
  • the method 100 in FIG.1 may start with the optional step 110.
  • step 110 an area to be fused is divided into at least two sets ⁇ ⁇ of locations ⁇ ⁇ , ⁇ .
  • the exact locations do not need to be known, yet, but the sections as a surface should be defined.
  • the sequenced set ⁇ ' ⁇ is intended/configured to be scanned by the ⁇ ⁇ -beam according to the sequence defined by the se- quenced set ⁇ ' ⁇ .
  • G ⁇ , ⁇ ,2 is a predetermined length of a time Lohr, Jöstingmeier & Partner SLM 2024/01 WO Page 19 / 38 21 March 2025 interval and GH ⁇ , ⁇ I, G are measures for estimates of the points in time when the locations ⁇ ⁇ , ⁇ and A 2 ⁇ are expected to be irradiated by the ⁇ ⁇ - or 4 ⁇ -beam source, respectively.
  • This at least one subsequence ⁇ 7 ⁇ can be considered as a path of neighbored locations ⁇ : ⁇ , ⁇ to be scanned according to their respective po- sitions in the subsequence ⁇ 7 ⁇ .
  • a beam spot is moved along the path in the sequence of the locations ⁇ : ⁇ , ⁇ .
  • this path can be stored as an array of locations ⁇ : ⁇ , ⁇ and/or as well be defined by a start point and end point and shape of the path (e.g. a straight line from the start point to the end point).
  • FIG.2 shows a powder bed 200 of fusible material 312 (see FIG.6).
  • Arrow ⁇ ⁇ ⁇ symbolizes an inert gas flow over the powder bed 200.
  • An area 210 of the pow- der bed symbolizes a cross section of a workpiece to be manufactured. Hence, the area 210 is to be scanned.
  • the number 3 is only an example, and any other number may be chosen as well.
  • the sections are simple subareas of the area 210, but to be able to scan these with a beam spot, the locations ⁇ ⁇ , ⁇ are sequenced and thereby sequenced sets ⁇ ' ⁇ are obtained. During this sequencing it is considered if a location ⁇ ⁇ ⁇ , ⁇ is lo- cated in the vicinity of another location ⁇ 2,), 4 ⁇ ⁇ . In the vicinity means in a Lohr, Jöstingmeier & Partner SLM 2024/01 WO Page 20 / 38 21 March 2025 spatial vicinity (? ⁇ , ⁇ ⁇ ⁇ 2, ⁇ ?
  • ⁇ ⁇ , ⁇ ,2) being indicated as sets 9 ⁇ ,2 of locations ⁇ ,m being in the vicinity of a location ⁇ 2, ⁇ , but as well incudes a temporal relation, i.e. At least some of these locations ⁇ , ⁇ are members of a sequenced subset ⁇ 7 ⁇ defining a path (see FIG.3) that is scanned by a beam source moving towards the relevant locations ⁇ 2 ⁇ ,) , which is herein as well re- ferred to as A 2 ⁇ or simply A 2 .
  • the relevant locations ⁇ 2,) are herein considered to define a set 9 2, ⁇ and can be rewritten as A 2 ⁇ , ⁇ or even shorter as or A 2 ⁇ if only a single ⁇ can be intended.
  • FIG.4 is as well a detail of a powder bed with an area to be scanned and similar notations are used as in FIG.2 and FIG.3.
  • the sequenced set of locations ⁇ ' ⁇ comprises sets of portions or in other words subsets. To declutter the figure, only a first portion 401 (a first subset 401) and a second portion 402 (a second subset 402) are shown.
  • the first portion 401 defines a line segment 401 that ex- tends at least essentially parallel to a ⁇ ⁇ preferential direction ⁇ ⁇ ⁇ .
  • the line segments 401, 402 may be irradiated by the ⁇ - beam in the direction being indicated by the arrow head.
  • the main spatter ejection direction (neglecting the gas flow) of the first portion points away from the neighbored section ⁇ ⁇ " ⁇ . Due to the gas flow, the spatter deposition is at least slightly turned towards the neighbored section ⁇ ⁇ " ⁇ .
  • the boundary n ⁇ , ⁇ " ⁇ extends parallel to the horizontal component ⁇ ⁇ ⁇ of the gas flow direction, but this not required, not even preferred, but has been cho- sen only for illustrative purposes.
  • spatter ejection direction points in the direction ⁇ ⁇ ⁇ . But again, it is not perpendicular to the gas flow direction of the horizontal compo- nent ⁇ ⁇ ⁇ of the gas flow across the powder bed. Hence, the distance from the boundary n ⁇ , ⁇ " ⁇ into which spatter deposition associated to the ⁇ ⁇ -beam source is reduced.
  • the error margin ⁇ o is preferably smaller or equal 45°e.g. ⁇ o ⁇ ⁇ 0°, 5°, 10°, 20°, 30°, 40°, 45° ⁇ .
  • the index ⁇ + 1 in the upper halfs of FIG. 4 and 5 has only been chosen to clearly distinguish from the example in the lower por- tion, that has been explained by reference to the section ⁇ ' ⁇ . Any portion of any section ⁇ 2 can be sequenced as explained with respect to the section ⁇ ⁇ " ⁇ , but as well with respect to the sectoin ⁇ ⁇ .
  • FIG.5 is almost identical to FIG.4, only the direction of the horizontal component ⁇ ⁇ ⁇ has been inverted. The technical effect obtained is the same and the descrip- tion of FIG.4 can be read on FIG.5 as well.
  • the additive manufacturing apparatus 300 in FIG.6 comprises a processor 301 to execute one or more methods being described herein and as well a memory 303 on which program instructions are stored for execution of one or more methods.
  • the additive manufacturing apparatus 300 is shown in a sectional view and has a process chamber 305, being enclosed by sidewalls 307, a bottom 308 and a ceil- ing 309. In the bottom 308 is an opening 381.
  • Below the opening 381 is movably supported support 382 as indicated by the double headed arrow 302.
  • the sup- port may be lowered by the thickness of a powder layer and a new powder layer may be applied, e.g. using a so called recoater, travelling over the opening 381.
  • a new powder layer may be applied, e.g. using a so called recoater, travelling over the opening 381.
  • the next surface 214 of the new upmost layer of the powder bed 200 of fusible material 312 may be irradiated using the beam sources 320 ⁇ .
  • surface 214 fumes occur at the locations ⁇ ⁇ , ⁇ of the surface 214.
  • Clause 1 A method for sequencing locations on a powder bed to be fused and/or for determining scanning paths of beams emitted by a number of at least two beam sources in a powder bed process, wherein the method comprises at least: d ividing an area to be scanned by the beams into a number ⁇ , ⁇ ⁇ 2 of Lohr, Jöstingmeier & Partner SLM 2024/01 WO Page 24 / 38 21 March 2025 sections ⁇ , ⁇ ⁇ ⁇ , wherein each section ⁇ is a set ⁇ of ⁇ ( ⁇ ) locations ⁇ , ⁇ to be irradiated by a ⁇ -beam source, i.e.
  • the method further comprises: - determining for at least one set ⁇ of locations ⁇ , ⁇ a subset 9 ⁇ , 9 ⁇ ⁇ ⁇ using the condition that for each location A ⁇ , A ⁇ ⁇ 9 ⁇ of the subset 9 ⁇ exists at least one location A2, 4 ⁇ ⁇ , 4 ⁇ ⁇ of at least one other sub- set 92, 92 ⁇ ⁇ 2 of another set of locations ⁇ 2,) with ?A ⁇ ⁇ A2?
  • ⁇ , ⁇ is a predefined minimum dis- tance
  • Clause 5 The method of one of the previous clauses and/or one of the claims be- low, characterized in that the sequencing step comprises at least: ( i) identifying a subset ⁇ R , ⁇ R R R R ⁇ ⁇ ⁇ ⁇ , with locations ⁇ ,] , ⁇ ,] ⁇ ⁇ that meet the conditions (ii) defining a forward direction u ⁇ pointing from a starting location ⁇ ⁇ R , ] ⁇ ⁇ R towards a location A with ?GHA I ⁇ G( ⁇ R ⁇ 2 2 ⁇ ,] )?
  • Clause 7 The method of one of the previous clauses and/or one of the claims below, characterized in that at least one of the sequenced locations ⁇ ( ⁇ ,) is a subset of locations ⁇ ⁇ , ⁇ .
  • Clause 12 An additive manufacturing apparatus, comprising a controller con- figured to execute a method of at least one of the previous method clauses 1 to 9 and/or the tangible memory of clause 11.
  • a controller con- figured to execute a method of at least one of the previous method clauses 1 to 9 and/or the tangible memory of clause 11.

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  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Chemical & Material Sciences (AREA)
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  • Physics & Mathematics (AREA)
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  • Toxicology (AREA)
  • Health & Medical Sciences (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • General Health & Medical Sciences (AREA)
  • Automation & Control Theory (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention concerne un procédé de séquencement d'emplacements sur un lit de poudre (200) à fusionner et/ou de détermination de trajectoires de balayage de faisceaux émis par un nombre d'au moins deux sources de faisceaux dans un procédé à lit de poudre comprenant au moins la division d'une zone à balayer par les faisceaux en un nombre n, n ≥ 2 de sections L q , q ≤ n, chaque section L q étant un ensemble de L q de k(q) emplacements l q, i à irradier par une source de faisceau q th et fournit un séquencement particulièrement efficace et donc une trajectoire de balayage si un ensemble L q d'emplacements l q, i un sous-ensemble S q , S q ⊆ L q est déterminé à l'aide de la condition selon laquelle il existe, pour chaque emplacement s q , s q ∈ S q <i /> du sous-ensemble S q un emplacement s p , p ≠ q, p ≤ n d'un autre sous-ensemble S p , S p ⊆ L p d'un autre ensemble L p d'emplacements l p, j avec |s q _ s p | ≤ d min, q, p et 1 ≤ j ≤ k(p), d min, q, p étant une distance minimale prédéfinie.
PCT/EP2025/057752 2024-03-28 2025-03-21 Détermination de trajet de balayage dans le processus de fusion de lit de poudre et appareil de fusion de lit de poudre Pending WO2025202045A1 (fr)

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3437762A1 (fr) * 2017-08-02 2019-02-06 Siemens Aktiengesellschaft Procédé et système de fabrication additive d'un composant
US20220193769A1 (en) * 2019-03-04 2022-06-23 SLM Solutions Group AG Control method, control device and production apparatus
WO2022223411A1 (fr) 2021-04-21 2022-10-27 SLM Solutions Group AG Fabrication additive par fusion de lit de poudre à équilibrage de charge entre de multiples faisceaux
DE102021129705A1 (de) * 2021-11-15 2023-05-17 Trumpf Laser- Und Systemtechnik Gmbh Verfahren, Planungsvorrichtung und Computerprogrammprodukt zum Planen einer lokal selektiven Bestrahlung eines Arbeitsbereichs mit einem Energiestrahl, sowie Verfahren, Fertigungsvorrichtung und Computerprogrammprodukt zum additiven Fertigen von Bauteilen aus einem Pulvermaterial
DE102022200167A1 (de) * 2022-01-10 2023-07-13 Eos Gmbh Electro Optical Systems Belichtungsstrategie an Scanfeldgrenzen
EP4467265A1 (fr) * 2023-05-25 2024-11-27 RTX Corporation Interaction laser-plume pour modèle de défaut prédictif pour fabrication additive par fusion de lit de poudre à lasers multiples

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Publication number Priority date Publication date Assignee Title
EP3437762A1 (fr) * 2017-08-02 2019-02-06 Siemens Aktiengesellschaft Procédé et système de fabrication additive d'un composant
US20220193769A1 (en) * 2019-03-04 2022-06-23 SLM Solutions Group AG Control method, control device and production apparatus
WO2022223411A1 (fr) 2021-04-21 2022-10-27 SLM Solutions Group AG Fabrication additive par fusion de lit de poudre à équilibrage de charge entre de multiples faisceaux
DE102021129705A1 (de) * 2021-11-15 2023-05-17 Trumpf Laser- Und Systemtechnik Gmbh Verfahren, Planungsvorrichtung und Computerprogrammprodukt zum Planen einer lokal selektiven Bestrahlung eines Arbeitsbereichs mit einem Energiestrahl, sowie Verfahren, Fertigungsvorrichtung und Computerprogrammprodukt zum additiven Fertigen von Bauteilen aus einem Pulvermaterial
DE102022200167A1 (de) * 2022-01-10 2023-07-13 Eos Gmbh Electro Optical Systems Belichtungsstrategie an Scanfeldgrenzen
EP4467265A1 (fr) * 2023-05-25 2024-11-27 RTX Corporation Interaction laser-plume pour modèle de défaut prédictif pour fabrication additive par fusion de lit de poudre à lasers multiples

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Title
CEN WEIHONG ET AL: "Modeling and simulation of the effect of scan strategy on spatter movement in laser powder bed fusion", THE INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY, SPRINGER, LONDON, vol. 132, no. 7-8, 12 April 2024 (2024-04-12), pages 3567 - 3578, XP037956042, ISSN: 0268-3768, [retrieved on 20240412], DOI: 10.1007/S00170-024-13596-7 *

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