Method for generating construction data for manufacturing a component based on a powder

Abstract

The invention relates to a computer-implemented method for producing construction data for producing a component (1) by means of a powder bed-based melting method, comprising: providing model data of the component (1) to be produced; providing a virtual structure space (2); creating an arrangement pattern (7) by placing and orienting the component (1) to be generated on the basis of the model data in the virtual structure space (2); determining a temperature distribution in the virtual structure space (2) for arranging the pattern (7), the temperature distribution characterizing an expected temperature distribution in the real volume space (4); generating model data of the hollow body (9) on the basis of the arrangement pattern (7) and the temperature distribution, the thermally loaded powder (8) being encapsulated with the hollow body (9) during the production of the component (1); adapting the arrangement pattern (7) on the basis of the one hollow body (9); construction data is extracted from the adapted arrangement pattern (7). The invention further relates to a method, a system (12) and a computer program.

Description

Technical Field

[0001] The invention relates to a computer-implemented method for generating construction data for producing a component using a powder bed-based fusion method.

[0002] Furthermore, the invention relates to a method for producing a component using a powder bed based fusion method. Likewise, the invention relates to a system for producing a component using a powder bed based fusion method. Furthermore, the invention relates to a computer program. Background Art

[0003] DE 10 2015 001 480 A1 discloses a method for producing a three-dimensional object by successively curing layers of at least one radiation-curable powdery building material on a building panel. By successively curing the or at least one radiation-curable powdery building material, at least one boundary element, which at least in sections traces the outer contour and / or the inner contour of the three-dimensional object to be produced, is formed to delimit a structural volume which at least in sections traces the outer contour and / or the inner contour of the three-dimensional object to be produced.

[0004] DE 102011121568A1 discloses a method for producing a three-dimensional object by solidifying a powdered building material by means of laser radiation at locations corresponding to the corresponding cross-section of the object. In an existing building room, a building unit is constructed, which tightly surrounds the object to be constructed either with at least one side wall of the building room or with other building unit wall sections, while the volume of the coating machine and the area coated by the coating machine are increasingly reduced, so that mainly only the area within the building unit is coated.

[0005] Furthermore, EP 3695957 A1 discloses a method for operating a device for producing three-dimensional objects by means of a layered structure.

[0006] For example, according to WO 2018 / 118009A1, the device may include a memory that may store instructions to cause a processor to generate a description of a first layer for each component that should be manufactured in the structural space of the 3D manufacturing device and a description of a second layer for the component. The processor can determine, using the description of the first layer, whether there is an arrangement that results in the components being assembled together in the structural space while providing a determined thermal decoupling space between the components. As a response to determining that the arrangement is not determined using the description of the first layer for the components, the processor can determine, using the description of the second layer, whether there is an arrangement that results in the components being assembled together in the structural space while providing a determined thermal decoupling space.

[0007] US2022 / 0040763A1 discloses a method for defining the structure of a blank with at least one object embedded therein. The method comprises: receiving three-dimensional data; defining at least one object; and identifying a flat surface in the at least one object based on the three-dimensional data. The orientation of the at least one object is defined so that the flat surface extends at least partially at the Z height of the blank. A mask pattern is defined for each layer so that at least one object is formed at the defined orientation using a powder material by an additive manufacturing method.

[0008] US2022 / 0288862A1 shows a shielded connector for circuit board assembly, which includes: contacts for circuit board assembly; a shell, which holds the contacts and has matching openings; a shielding sleeve, which surrounds the shell and has a first circuit board connection section near the rear end section, which is connected to a grounding pattern on the circuit board; a sleeve, which is configured to have a plug-in channel for plugging in a matching connector, wherein the plug-in channel is open forward and connected to the matching opening; and a grounding element near the front end section of the sleeve, which has a second circuit board connection section that can be connected to the grounding pattern on the circuit board. Summary of the invention

[0009] The object of the following invention is to improve the removal of bulk powder that has been subjected to excessive thermal stress after a component production process by means of a powder bed-based fusion method.

[0010] This object is achieved by a computer-implemented method according to the invention for generating construction data for manufacturing a component using a powder bed-based fusion method, a method for manufacturing a component using a powder bed-based fusion method, a system for manufacturing a component using a powder bed-based fusion method, and a computer program. Reasonable improvements are derived from the embodiments according to the invention.

[0011] One aspect of the invention relates to a computer-implemented method for generating construction data for manufacturing a component using a powder bed based fusion method, comprising the following steps:

[0012] - in particular providing model data of the component to be produced;

[0013] - in particular providing a virtual construction space having boundary dimensions which define the dimensions of an outer edge of the virtual construction space, wherein the virtual construction space reflects a real volume filled with powder in which the component to be produced is to be produced;

[0014] - creating at least one arrangement pattern by placing and orienting the components to be produced, in particular based on the model data in a virtual construction space;

[0015] - in particular determining a temperature distribution in a virtual structure space for the arrangement pattern, which temperature distribution characterizes the temperature distribution to be expected of the powder in the real volume space;

[0016] - generating model data of at least one hollow body to be produced, in particular based on the arrangement pattern and the temperature distribution, which hollow body can be arranged in the virtual construction space between adjacent components to be produced, or between at least one component to be produced and an outer edge of the virtual construction space, wherein during the production of the component, the hollow body can be used to encapsulate a heat-loaded powder located within the hollow body;

[0017] - adapting the arrangement pattern, in particular on the basis of at least one hollow body to be produced;

[0018] - in particular extracting construction data from the adapted layout pattern; and

[0019] - In particular, the extracted construction data is provided.

[0020] The proposed method makes it possible to generate or produce construction data for producing a component in such a way that, when the component is subsequently produced by means of a powder bed-based fusion method, the powder remaining after the production of the component and which is too strongly thermally loaded can be removed more easily. Advantageously, at least one hollow body is used here, because it is also produced during the production of the component and surrounds or encapsulates the powder that is too strongly thermally loaded. As a result, after the production of the component, the at least one hollow body or the plurality of hollow bodies can be removed manually or automatically, so that the powder contained therein can be removed. Ultimately, only loose powder remains, which can be used again in a subsequent production method with an unchanged powder quality.

[0021] By means of the method according to the invention, a software tool for a powder bed-based fusion method can be provided, with which thermally loaded powders can be packaged in order to achieve maintenance of the powder quality.

[0022] In the additive production of plastic components, such as, for example, in powder bed-based methods, selective laser sintering (SLS) and multi jet melting (MJF), surrounding unsolidified powder can be reused. This powder may be thermally loaded, so that the powder properties may no longer correspond to those of the initial powder. The thermal load depends on the current packing density and the component arrangement as well as the structural space. As a result of the reduction in powder quality caused by the thermal load, the component quality may decrease and the scrap rate increase. In particular, powder areas that are strongly thermally loaded lead to a reduction in powder quality. In areas where there is a strong thermal load, hollow bodies can be provided according to the invention. With the help of hollow bodies that can be produced synchronously with the production of the component, powder that can no longer be reused can be encapsulated.

[0023] By the method according to the invention, the decision of the operator in powder removal can be omitted. So far, powder removal is carried out based on empirical knowledge, wherein the amount of powder is reused or removed depending on the operator. Here, assistance can be provided by a computer-implemented method. So far, no objective approach or support has been provided to the operator in this regard when removing powder. Now, this support is provided by a computer-implemented method or at least one or more hollow bodies that are additionally provided. Powder removal and powder removal based on empirical values ​​lead to increased material consumption and lower powder utilization. This can also be actively improved by the proposed method. In addition, by the proposed method, improvements in powder quality can be achieved, because so far, due to the subjective decision-making process when removing the amount of powder, undefined powder quality may exist. By encapsulating a powder medium that is too strongly thermally loaded with the help of one or more hollow bodies, an unchanged, especially high powder quality of the powder to be reused can be achieved.

[0024] In particular, by means of the proposed method, powder regions that are too strongly thermally loaded can be automatically encapsulated, so that the operator can clearly identify these powder regions and remove them as closed hollow bodies. Subjective decision-making processes and a reduction in the powder quality can thus be avoided. A uniform powder quality can be maintained and powder that is too strongly thermally loaded is not reused. In addition, the amount of powder to be removed is surrounded by a capsule (i.e. a hollow body), so that the removal can be significantly improved. By introducing hollow bodies (such as capsules, for example), it is possible to distinguish between different powder regions, so that by automatically or manually removing the hollow bodies, after the component is manufactured, only powder that can be used in a subsequent manufacturing process with high quality is still present.

[0025] The method according to the invention can avoid the reuse of powders that are too strongly thermally loaded or the removal of powders that are still valuable in terms of quality. By introducing one or more hollow bodies, a separation between powder qualities can be achieved within the construction space. This can achieve a uniform powder quality, a higher powder utilization rate, a low amount of powder removal and a defined powder quality, which can have a positive effect on the reproducibility of component properties. Based on the layout pattern and the temperature distribution of the components to be produced within the virtual construction space, it is possible to identify and, in particular, simulate the intervals or regions that cause high temperature inputs to the powder there in the subsequent manufacturing process.

[0026] Powder bed-based fusion is a type of additive manufacturing method. In additive manufacturing methods, materials are usually joined layer by layer in order to produce a workpiece from 3D model data. Methods of this type include manufacturing processes in which thermal energy selectively connects or melts regions of a powder bed. The construction data specify, in particular, at which locations the powder is melted. For example, the model data are computer-aided design (CAD) data. The boundary dimensions of the virtual construction space give the dimensions of the real volume space. The component is produced in this real volume space.

[0027] The creation of at least one arrangement pattern can be referred to as "nesting?". For example, a computer-implemented method such as software can be used in this case to generate model data (in particular of the arrangement pattern). When determining the temperature distribution in the construction space, calculations or simulations can be performed to determine what temperatures exist in the real volume space when the component is manufactured. This temperature distribution can be generated as a function of size, orientation, arrangement or device properties.

[0028] After the arrangement pattern associated with the component to be produced is created and thus generated, it can be determined or determined in which areas there is a higher temperature input and thus the powder here can be loaded by the arrangement and in particular the distribution of the components and the measured temperature distribution. In the area between adjacent components or between a component and the outer edge of the virtual space, consideration can be given to the generation of hollow bodies. Thus, for example, a hollow body filling the gap can be generated between two or more adjacent components. Thus, powder that is predicted to be too strongly loaded here can be encapsulated accordingly. In particular, a plurality of hollow bodies can be provided. Subsequently, the arrangement pattern can be adapted again based on at least one hollow body. Thus, construction data can be extracted accordingly, so that at least one hollow body can be manufactured simultaneously or synchronously when manufacturing the component.

[0029] For example, the temperature distribution in the virtual structure space can be calculated by means of a finite element method (FEM) algorithm. This temperature distribution can thus be simulated better. The deviation between the real temperature value and the simulated temperature value can be kept small. For example, the deviation is less than 10%, in particular less than 5%, in particular less than 1%.

[0030] For example, the temperature distribution can be determined and in particular outputted in a time-dependent manner for a simulated printing process. In other words, the temperature distribution can be determined not only in a position-dependent manner but also in a time-dependent manner for a simulated printing process. During a printing process (also referred to as a printing process), the temperature can change over time. For example, a lower layer that has already been printed cools over time. By taking into account the time dependency of the printing process, a simulation that is close to reality can be achieved.

[0031] The method according to the invention can be used, for example, as a software supplement and / or as a stand-alone software tool for targeted maintenance of powder quality with strict separation of powder quality within the construction space. The method according to the invention can be applied to all powder-based, additive manufacturing methods for plastic, metal or ceramic components, such as, for example, "SLS" ("Selective Laser Sintering"), "MJF" ("Three-Beam Material Coating", "Material Jetting"), "SLM" ("Selective Laser Melting") or "Binder Jetting".

[0032] By means of the method according to the invention, subjective decisions regarding the reuse of powder can be avoided by objective evaluation. In addition, a strict separation can be implemented between powder qualities. In addition, different parameters or target parameters can be preset or determined manually or on the system side when manufacturing and designing hollow bodies. By means of the encapsulation of the hollow bodies, the quality of the old powder can be set in a targeted manner. Since powder that is too strongly loaded can be removed accordingly, material benefits can be achieved. By encapsulating the powder to be thermally loaded, other areas with powder can be isolated relative to the powder, so that material protection can be achieved. This can achieve an increase in component quality and reproducibility. Encapsulated, especially loose powder, can be easily removed.

[0033] The computer-implemented method according to the invention can be integrated into existing construction preparation software. By encapsulating the powder to be removed, material removal and a reduction in material costs can be achieved. The powder thus left can be reused in a subsequent manufacturing method or process with a uniform powder quality.

[0034] In one embodiment, it is arranged that, based on the temperature distribution, a virtual gap formed in the virtual structural space between at least the components to be generated and between the components to be generated and the outer edge of the virtual structural space is divided into a plurality of regions, and respective target values ​​of the temperature distribution are preset for these regions. Model data of at least one hollow body is generated based on these regions, and in particular the hollow body can be arranged within the virtual gap. In other words, the virtual gap can be a space in which no components are provided. Thus, in terms of the virtual structural space, the entire area in which the structural space is not placed or positioned can be used as a virtual gap. Thus, each individual area extending between the components and / or between the components and the outer edge can be counted as a virtual gap.

[0035] The virtual gap can be divided into a plurality of regions, i.e. virtual sub-regions. For this division, respective target values ​​can be provided or preset for the respective regions in view of the temperature or temperature distribution existing there. This is important because, after the subsequent manufacturing process of the component, the virtual intermediate region is a region containing loose powder that can be reused. Thus, by means of the division of these regions and the independent temperature values, it can be determined in which of these sub-regions or regions there is a high temperature input or a high temperature. In regions where there is a higher temperature or a higher temperature input, the hollow body can be placed again, because it is expected that the loose powder that eventually remains here will be too strongly thermally loaded and should be removed accordingly.

[0036] For the respective regions, a target value for the temperature of the powder in the respective region can be preset. In particular, in the real gap and the real volume space, the corresponding target value for the temperature of the powder should be reached. The preset is performed, for example, by an operator. It is also possible that the preset is performed by a "machine learning algorithm". For this purpose, parameters such as material properties of the powder and the printing device can be considered. The target value can be, for example, a temperature maximum value, or a specific distribution, for example involving a uniform temperature distribution. For example, if a target value is preset for a uniform temperature distribution, the powder temperature in the virtual construction space and therefore also in the real construction space should be the same.

[0037] In particular, it can also be set as a target value that the gap is subjected to the most uniform temperature load possible. In other words, it is possible to set not only quantitative target values ​​but also qualitative target values. In particular, the target values ​​are set in such a way that the remaining powder quality is optimized. This minimizes the waste of powder. This allows the old powder to be used for a longer time and has a controlled quality of the old powder.

[0038] For example, the virtual structure space may be divided into voxels or voxel groups. In other words, the virtual structure space may be divided into grid points by means of a three-dimensional grid. A grid point may be referred to as a voxel. A plurality of voxels may form a voxel group. For a single voxel and / or a single voxel group, a specific temperature value may be given as a target value. For example, the mentioned area of ​​the virtually divided gap may be such a voxel.

[0039] This results in the advantage that individual voxels and / or voxel groups are subjected to a more intense thermal load in order to protect other voxels or voxel groups. This can prevent, for example, a powder quantity from being unusable due to excessive thermal load.

[0040] For example, consideration can be given to the creation of hollow bodies based on the voxels which are located within the gap and which in turn have a high temperature load.

[0041] For example, after the components have been placed and oriented in the construction space according to the pre-sets and the laser profile or heating interval is known, a special classification of the voxels can be performed in view of the expected thermal load of the material. In this case, the thermal load can be described by the distance of the voxels or voxel groups from the laser track (Laserbahn). The denser the voxels are at the laser track, the higher the thermal load, so that powder should be removed here and should be encapsulated by hollow bodies. It is also conceivable to take into account the packing density in the construction space, that is, how many components are placed in this construction space, wherein this packing density may produce a temperature hysteresis and thus may load the powder more strongly with heat. This situation can also be taken into account when generating data for at least one hollow body or multiple hollow bodies. In the case where the laser track and the distance of the voxels generated thereby from the corresponding laser track are already known, a specific temperature, that is, a target value for the temperature distribution, can be assigned or allocated to the voxels and / or voxel groups.

[0042] For example, a division into cold, warm or hot areas can be performed. It is also conceivable to divide into temperature ranges, such as, for example, 20 to 100°C, 101 to 150°C, 151 to 170°C or 171 to 200°C. The higher the temperature input in the divided area, the stronger the loading on the powder there. In addition, the area can be selected according to the corresponding melting temperature and crystallization temperature of the material used. Boundary values ​​or thresholds, such as absolute temperatures or intervals, can be defined from now on, at which the volume pixels or volume pixel groups are automatically surrounded by hollow bodies. This situation can be taken into account when generating model data. For example, in the process of manufacturing components with the aid of lasers, as in the manufacture of components, the corresponding volume pixels can be processed around by the laser, and a hollow body can be formed thereby, and the heat-loaded powder contained therein can be surrounded. Subsequently, when removing the powder later, the operator or the automated device can identify and remove the hollow body.

[0043] In one embodiment, it is provided that at least one hollow body is arranged in a virtual gap so that the outer contour of the hollow body at least partially abuts against the adjacent component to be produced in a directly spaced manner, or the outer contour of the hollow body at least partially abuts against at least one component to be produced and the outer edge of the virtual structural space in a directly spaced manner. Since the temperature input between the components to be produced or between the component and the outer edge is the largest and the powder is strongly thermally loaded here, the hollow body is placed or positioned here so that the powder thermally loaded here is at least partially, especially completely surrounded or encapsulated by the hollow body. For this purpose, the outer contour of the hollow body can abut against the components arranged around in a directly spaced manner. For example, the hollow body can be arranged between two components, and the hollow body can have a minimum distance from the adjacent components at its outer contour. For example, the minimum distance can be preset by a laser track or a laser beam. As a result, between the two components, the powder strongly loaded here can be encapsulated by the hollow body and then removed.

[0044] For example, in order to generate the outer contour of the hollow body, the laser path can be arranged or configured in such a way that it is adapted to the contour of the component or the current thermal load of the powder. The width or thickness of the laser path is thus predetermined as a distance between the hollow body and the contour of the component. In this way, the powder which is thermally loaded here can be surrounded as completely as possible by the hollow body without wasting installation space.

[0045] In one embodiment, it is provided that at least one hollow body is arranged in the virtual gap in such a way that the hollow body has a predetermined distance from the adjacent component to be produced, or the hollow body has a predetermined distance from at least one component to be produced and the outer edge of the virtual construction space. For example, the predetermined distance can be predetermined by the laser track and in particular by the width of the laser track. As a result, the hot loaded powder can be enclosed as much as possible by means of the hollow body. However, a minimum distance should be given between the hollow body and the construction space or the outer edge, because otherwise the hollow body and the component will fuse.

[0046] In one embodiment, it is provided that the wall thickness of the hollow body is adapted based on the temperature distribution between adjacent components to be generated in the virtual space or between at least one component to be generated and the outer edge of the virtual structural space, and is taken into account when generating the model data of the hollow body. As a result, for example, the hollow body can be shielded relative to the adjacent components. Here, the wall thickness can be selected independently by the operator or automatically generated by the software or system. For example, the wall thickness range can be between 100 μm and 1000 μm. Particularly advantageous is a wall thickness of, for example, 500 μm. In particular, the wall thickness can be designed to be as small as possible in order to avoid additional thermal loads on the surrounding powder. In addition, the wall thickness can be designed to be continuous or variable, which can be done on the system side, for example.

[0047] The distance between the laser track of the hollow body and the component can be kept as small as possible in order to incorporate as much of the intensely thermally loaded powder as possible, i.e. to push it through the hollow body. For example, the laser track for producing the hollow body and the laser track for producing the component can have a distance of 100 μm. Joints or connections between the component and the hollow body should be avoided.

[0048] In one embodiment, it is provided that the geometry of the hollow body is determined based on the temperature distribution in the virtual construction space between adjacent components to be produced or between at least one component to be produced and an outer edge and an arrangement pattern of the virtual construction space, wherein this is taken into account when generating model data for the hollow body.

[0049] The shape of the hollow body or the design of the hollow body can be designed or determined in such a way that the thermally loaded powder can be enclosed or surrounded as completely as possible. For example, the design of the hollow body or hollow element can occupy a predefined body, such as a cube, a sphere, a pyramid or other geometric shapes. Likewise, the design or shape of the hollow body can be arbitrary and thus freely defined. This can again be achieved by software.

[0050] In particular, the hollow body is designed to be based on the diffusion of powders that are too strongly thermally loaded. Completely undefined contours are also conceivable. Likewise, the outer shell of the hollow body can be smooth or irregular. Likewise, the outer shell of the hollow body can be rough or have a defined feel. In particular, the hollow body should be designed in such a way that it is different from the component and, in particular, different from the component design, so that the hollow body can be easily identified and removed accordingly.

[0051] For example, the shape can be preset on the system side or manually.The laser parameters for producing the hollow body (ie the laser parameters of the laser for melting the powder) can correspond to the parameters for producing the component or can be freely selected.

[0052] It is also conceivable that the parameters are not designed for the highest possible component quality, but for the fastest possible, not too high quality surface quality of the hollow body. This can keep the energy input or expenditure for producing the hollow body very low, because the hollow body is then separated and not used for applications like components.

[0053] Furthermore, the laser speed and the laser intensity can be minimized for the production of the hollow body. It is also conceivable that the outer contour of the hollow body requires a high surface quality in order to avoid connections with other components and to achieve the smallest possible laser track distance between the hollow body and the component. Accordingly, the inner contour (i.e., which faces the thermally loaded powder) can be produced with a less high quality. It is also conceivable that the hollow body is provided with markings, such as text or symbols, on its outer surface in order to clearly identify or mark the hollow body as a component to be removed. Likewise, the marking can be produced by melting the powder with the aid of a laser.

[0054] Another possibility for generating model data for hollow bodies is to consider regions or pixel bodies. For example, it can be provided that starting from a certain accumulation of pixel bodies that are too strongly thermally loaded, these pixel bodies should be automatically combined with hollow bodies. It is conceivable that when the amount of powder classified as strongly thermally loaded powder is more than 1 gram, this powder should be automatically surrounded by hollow bodies.

[0055] The powder for the contour of the hollow body can be assigned to a powder that is too strongly thermally loaded or to a powder that can theoretically be reused. This can be done by an operator or by software. The software or computer program for the implementation of the computer-implemented method can be used as stand-alone software in the construction preparation or as a supplement to existing software tools for construction preparation. In the construction data to be generated, it must be taken into account that the hollow body only surrounds the loose powder, but not the component to be produced.

[0056] In one embodiment, it is provided that as construction data, structural data, in particular CAD data, are provided, which indicate at which locations in the powder thermal energy is introduced into the applied powder layer by a directed energy source in order to selectively connect or fuse the powder at these locations. The energy source may be a laser.

[0057] For example, the actual temperature during the printing process can be monitored. For example, the temperature is measured by means of an optical temperature sensor. The measured temperature values ​​can be provided as input parameters to the machine learning algorithm. This makes it possible to check whether the determined temperature distribution corresponds to the measured temperature values. In addition, the presetting of the respective temperature target can be improved.

[0058] Another aspect of the invention relates to a method for producing a component using a powder bed-based fusion method, comprising the following steps:

[0059] - applying the powder as a powder bed onto the support;

[0060] - selectively applying heat to the powder by means of a directed energy source in accordance with the construction data generated according to any of the above-described methods according to the invention;

[0061] - remove powder; and

[0062] - supplying reusable powder as part of the removed powder for the next manufacturing cycle;

[0063] This allows a production method that saves powder and uses powder efficiently. Powder waste can be significantly reduced. Components can also be produced more accurately in shape. In particular, the density of the components produced in this process is also increased.

[0064] The powder is applied to the support as a powder bed according to the construction data. In particular, the construction data are determined and provided according to the method described above. The removal of the powder can be referred to as "de-powdering". In particular, the removed powder can be reused. The method for generating construction data should be improved by the quality and quantity of the reusable powder.

[0065] In particular, loose powder without thermal load can be removed on the one hand. Powder that is too heavily loaded can also be removed again by removal or by removing the hollow body.

[0066] Another aspect of the invention relates to a system for carrying out the method according to the aforementioned aspect and advantageous developments. Here, the system can have a memory unit, an evaluation unit and an output unit, wherein the system is designed to carry out the steps of the method according to the aforementioned aspect.

[0067] In particular, the system described above can implement the method mentioned above.

[0068] Another aspect of the invention relates to a computer program having commands which, when executed by a computer, cause the computer to execute the method according to the aforementioned aspect and advantageous further developments, and which can be loaded into a memory unit and executed by a processor. In particular, the computer program described above can be used to generate construction data using the computer-implemented method mentioned at the outset.

[0069] For application cases or application scenarios that are available in the method and are not explicitly described here, it can be provided that according to the method, an error message is output and / or a request is made to input a user feedback and / or a standard setting and / or a predetermined initial state is set.

[0070] The present invention also includes improvements of the system according to the invention and of the computer program according to the invention, which have the features already described in conjunction with the improvements of the method according to the invention. For this reason, the corresponding improvements of the system according to the invention and of the computer program according to the invention are not described again here.

[0071] The invention also includes combinations of features of the described embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0072] The following describes an embodiment of the present invention.

[0073] Figure 1 A schematic flow chart of an embodiment for generating construction data for manufacturing a component is shown;

[0074] Figure 2 A schematic top view of a real volume space with components and hollow bodies to be produced is shown;

[0075] Figure 3 A schematic diagram of a virtual structural space with a hollow body arranged between two components is shown;

[0076] Figure 4 Another schematic embodiment of the arrangement of components and hollow bodies in a virtual structural space is shown;

[0077] Figure 5 Shows Figure 4 An exemplary detail diagram of the virtual structure space in FIG.

[0078] Figure 6 A schematic diagram of a square hollow body is shown;

[0079] Figure 7 Shows Figure 6 A schematic cross-sectional view of a hollow body in FIG.

[0080] Figure 8 A schematic diagram of a hollow body in the shape of a cylinder is shown;

[0081] Fig. 9 Shows Figure 8 A schematic cross-sectional view of a hollow body in FIG.

[0082] Fig.10 Another feasible design of the hollow body is shown;

[0083] Fig.11 Shows Fig.10 A schematic cross-sectional view of a hollow body in FIG.

[0084] Fig.12 Another embodiment of a hollow body having an inner opening or inner region is shown; and

[0085] Fig.13 Shows Fig.12 Schematic cross-sectional view of a hollow body. DETAILED DESCRIPTION

[0086] The embodiments explained below are preferred embodiments of the present invention. In the embodiments, the components described are individual features of the present invention that can be considered independent of each other, which also improve the present invention independently of each other, and are therefore also considered as components of the present invention individually or in a combination different from the combination shown. In addition, the described embodiments can also be supplemented by other features of the already described features of the present invention.

[0087] In the figures, functionally identical elements are respectively provided with the same reference symbols.

[0088] Figure 1 A schematic flow chart of an exemplary embodiment of a method according to the invention or a simulation method for generating construction data for producing a component using a powder bed-based fusion method is shown.

[0089] In an optional step S1, a component 1 to be produced can be provided (see Figure 2 ). For example, the model data can be provided as CAD data. In a subsequent optional step S2, a model with boundary dimensions 3a, 3b, 3c (see Figure 3 ) virtual structure space 2 (see Figure 3 ). The boundary dimensions 3a, 3b, 3c may define the dimensions of the outer edges of the virtual structure space 2. The virtual structure space 2 may reflect the real volume space 4 (see Figure 2 ). Powder 5 can be used virtually (see Figure 2 ) fills the real volume 4. The component 1 to be produced can be produced in or with the powder 5.

[0090] For example, a virtual gap 6 (see Figure 3 ) A virtual gap 6 can be formed in the virtual construction space 2 between the components 1 to be produced and between the components 2 to be produced and the outer edge of the virtual construction space 2.

[0091] In a further step S3, at least one arrangement pattern 7 is created by placing and orienting the components 1 to be produced in the virtual construction space 2, in particular according to target values ​​based on the model data (see Figure 3 ).

[0092] In a further optional step S4 , the temperature distribution in the virtual construction volume 2 can be determined for the arrangement pattern 7 . This temperature distribution can characterize the temperature distribution of the powder 5 that can be expected in the real volume 4 .

[0093] Depending on the temperature distribution, for example, zones such as cold or hot areas can be defined. To this end, in an optional fifth step S5, parameters for component production such as laser speed, laser intensity, heating zones or layer thicknesses can be provided.

[0094] During the production of the component 1, a temperature input can be applied to the loose powder 5 surrounding the component 1. The temperature input can load the powder so strongly, especially thermally, that it can no longer be reused in a subsequent production process. For this purpose, the thermally loaded powder 8 (see Figure 2 ) can be encapsulated or surrounded by means of a hollow body 9. This can again be done in optional step S6. Here, model data of a hollow body 9 or a plurality of hollow bodies can be generated. The hollow body can be arranged in an adjacent component 10 to be manufactured (see Figure 2 ). It is also conceivable that the hollow body 9 can be arranged between at least one component 1 and the outer edge of the virtual structural space 2. In order to generate the model data, the layout pattern 7 and the temperature distribution can be taken into account. When manufacturing the component 1, the hollow body 9 can be manufactured synchronously, so that the heat-loaded powder 8 can be encapsulated in the hollow body. After the component 1 is manufactured, the heat-loaded powder 8 can be removed by removing the hollow body 9 and is not used again.

[0095] Since the at least one hollow body 9 can be generated in particular only after the arrangement pattern 7 has been generated, the adaptation of the arrangement pattern 7 can be carried out after the model data of the hollow body 9 have been generated.

[0096] With regard to the provision or determination of the hollow body 9, parameters or input parameters that can be used for the production or use of the hollow body 9 can be provided in an optional step S7. In order to determine which area has a higher temperature input, the virtual structural space 2 can be divided or partitioned into voxels 11 and / or voxel groups 12. For example, a voxel 11 is a square, in particular cubic, volume unit within the virtual structural space 2. In particular, the voxels 11 are of equal size. For example, a plurality of voxels 11 can form a voxel group 12. The temperature or temperature distribution therein can be simulated or preset for each of these voxels. In this way, areas or intervals having a high temperature and, correspondingly, having a heat-loaded powder 8 can be detected or determined. In this step S7, for example, the wall thickness 13 that the hollow body 9 should have can be preset (see Figure 2) as a parameter. Likewise, a collection of body pixels 11 and / or body pixel groups 12 can be preset. If a temperature threshold is reached and / or exceeded within adjacent body pixels 11, the body pixels 11 can be automatically encapsulated by means of at least the hollow body 9. Likewise, a laser speed and / or a laser intensity of a laser can be provided. Likewise, the design, shape and / or geometry of the hollow body 9 can be preset or specified. Likewise, a distance between the component 1 and a laser track 15 can be preset. The laser track 15 is the contour of the laser 14 used for melting powder, in particular for producing the component 1. The laser track 15 can again be regarded as the distance between the contour of the component 1 and the hollow body 9.

[0097] In an optional step S8 , construction data can be extracted and in particular provided based on the adapted arrangement pattern 7 .

[0098] Figure 2 An example is shown for a volume 4. A component 1 to be produced or already produced is shown in a top view. On the one hand, it can be seen here how three components 10 are arranged so that a gap is formed which can have a powder 8 which is too strongly thermally loaded and is encapsulated by means of hollow bodies 9. Furthermore, components 16 are positioned very close together so that a hollow body 17 is also arranged between them at least in places.

[0099] The arrangement pattern 7 is a possible solution for how the components 1 to be produced can be placed and oriented within the virtual construction space 2. In this case, it may be necessary in particular that boundary conditions can be met. Possible boundary conditions are, for example, that the components 1 to be produced may not intersect and / or that a minimum distance from each other and / or a minimum distance from the outer edge of the virtual construction space 2 must be maintained between the components 1 to be produced and / or that a minimum number of components 1 to be produced must be arranged within the virtual construction space 2.

[0100] Based on the extracted construction data, the component 1 can be manufactured in a real manufacturing method by means of the system 17 or a printing device (which can in turn be a laser or a laser device). The component 1 can be produced by melting based on a powder bed. In particular, at least one powder layer can be applied for this purpose. Subsequently, the powder layer can be heated locally by means of a laser 14 or a thermal energy source. The heated powder 4 then melts. Then, the next powder layer can be applied. According to the adapted arrangement pattern 7 and in particular the hollow bodies 9, 17, it can be achieved that the heat-loaded powder 8 that is not required for the manufacture of the component 1 is correspondingly dealt with or encapsulated so that it can be removed immediately afterwards. In addition, there may be areas that may contain powder that is not heat-loaded due to the distance from the component 1, such as the area 18. This can be used again in the subsequent manufacturing process. The system for manufacturing components and in particular for generating construction data can, for example, have a memory unit 20, an evaluation unit 21 and an output unit 21.

[0101] As already mentioned, in Figure 3 2 shows a schematic diagram of a virtual construction space 2. Here, a virtual gap 6 is shown by way of example, in which no component or hollow body is present. Here, two components 1 are arranged one on top of the other, and between them there is a hollow body 9 with a powder 8 that is too strongly thermally loaded.

[0102] exist Figure 4 Another exemplary illustration of a virtual construction space 2 can be seen in FIG. A cross-sectional view is shown here. Here, a plurality of components 1 are arranged closely to one another. In the region between the components 1, a plurality of hollow bodies 9 are provided, since the close arrangement of the components 1 causes the powder located between them to be too strongly thermally loaded and must be removed after the production process of the components 1.

[0103] exist Figure 5 In, again from Figure 1 A detailed view or a section can be seen from the beginning. Here, a hollow body 9 and the thermally loaded powder 8 contained therein can be seen between two components 1. In the surroundings, there can be weakly loaded powder 5. Between the hollow body 9 and the component 1, a predetermined distance 23 can exist or be provided. In particular, the hollow body 9 should not be in contact with the component 1.

[0104] In cross section, the hollow body 9 or the encapsulation can have a wide variety of geometric designs in terms of cross section. For example, square, circular, rectangular, triangular or stepped shapes are conceivable. In particular, any shapes are conceivable. The hollow body 9 can be rotationally symmetrical or completely random or arbitrary. Likewise, the hollow body can be translationally symmetrical.

[0105] exist Figure 6 An example of a hollow body 9 in the form of a square is shown in FIG. Figure 7 , a sectional view is again shown, so that the hollow body 9 and the hot-loaded powder 8 contained therein are shown in the periphery.

[0106] exist Figure 8 The hollow body 9 is shown again as a cylinder. Fig. 9 , a cross-sectional view is again shown, in which the powder 8 contained in the cavity can be seen.

[0107] exist Fig.10 , a random or shapeless geometry of the hollow body 9 is shown again. In particular, the shape can be adapted as desired depending on the design of the arrangement pattern 7 and in particular the arrangement and temperature distribution of the component 1. Fig.11 Again, the Fig.10 The illustration in the figure shows the relevant cross section.

[0108] exist Fig.12Another conceivable design of the hollow body 9 is shown in FIG. Here, the hollow body 9 can have an internal opening. In this opening 24 or in this inner region, powder that has been subjected to less intense heat input can be present. Fig.13 (It shows Fig.12 As can be seen in the cross-sectional view of the hollow body 9 shown in FIG, heat-loaded powder 8 is present between the outer contour of the hollow body 9 and the opening 24. Powder that can also be reused can be present again within the opening 24. The shape or design of the hollow body 9 can thus be adapted or changed as desired, depending on the design of the construction data and in particular on the circumstances or the production of the component by means of a melting method. It can thus be ensured, depending on the manufacturing circumstances or the application, that powder 8 that is too strongly heat-loaded is not used in further processing steps. This is achieved by encapsulating the powder 8 by means of the hollow body 9.

[0109] Reference numerals list:

[0110] 1 Component

[0111] 2 Virtual Structure Space

[0112] 3. Border size

[0113] 4 Real Volume Space

[0114] 5. Powder

[0115] 6 Virtual Gap

[0116] 7. Layout Pattern

[0117] 8. Heat-loaded powder

[0118] 9 Hollow Body

[0119] 10 components

[0120] 11 voxels

[0121] 12 voxel groups

[0122] 13 Wall thickness

[0123] 14 Lasers

[0124] 15 laser tracks

[0125] 16 components

[0126] 17 Hollow Body

[0127] 18 Area

[0128] 19 Systems

[0129] 20 memory cells

[0130] 21 evaluation units

[0131] 22 output units

[0132] 23Distance

[0133] 24 openings

[0134] Steps S1 to S8

Claims

1. A computer-implemented method for generating construction data for manufacturing a component (1) using a powder bed-based fusion method, comprising the following steps: - providing model data of the component (1) to be produced; - providing a virtual construction space (2) having boundary dimensions (3a, 3b, 3c) defining the dimensions of the outer edges of the virtual construction space (2), wherein: The virtual construction space (2) reflects a real volume space (4) filled with powder (5) in which the component (1) to be produced is to be produced; - creating at least one arrangement pattern (7) by placing and orienting the component (1) to be produced based on the model data in the virtual construction space (2); - determining a temperature distribution in the virtual structure space (2) for the arrangement pattern (7), said temperature distribution characterizing the expected temperature distribution of the powder (5) in the real volume space (4); - based on the arrangement pattern (7) and the temperature distribution, generating model data of at least one hollow body (9, 17) to be produced, wherein the hollow body can be arranged in the virtual structural space (2) between adjacent components (1, 10, 16) to be produced, or between at least one component (1, 10, 16) to be produced and an outer edge of the virtual structural space (2), wherein the hollow body (9, 17) can be used to encapsulate heat-loaded powder (8) located inside the hollow body (9, 17) when manufacturing the component (1); - adapting the arrangement pattern (7) based on the at least one hollow body (9, 17) to be produced; - extracting the construction data from the adapted layout pattern (7); and -Provide the extracted construction data.

2. The method according to claim 1, wherein: Based on the temperature distribution, a virtual gap (6) formed in the virtual structural space (2) between at least the components (1) to be produced and between the components (1) to be produced and the outer edges of the virtual structural space (2) is divided into a plurality of regions (11, 12), and respective target values ​​of the temperature distribution are preset for the regions, wherein model data of at least one hollow body (9, 17) is generated based on the regions (11, 12), in particular the hollow body (9) is arranged within the virtual gap (6).

3. The method according to claim 2, wherein: The at least one hollow body (9, 17) is arranged in the virtual gap (6) such that The outer contour of the hollow body (9, 17) at least partially bears against the adjacent component (1, 10, 16) to be produced in a directly spaced manner, or The outer contour of the hollow body (9, 17) at least partially bears against the outer edges of the at least one component (1) to be produced and the virtual installation space (2) in a directly spaced manner.

4. The method according to claim 2 or 3, wherein: The at least one hollow body (9, 17) is arranged in the virtual gap (6) such that The hollow body (9, 17) has a predetermined distance (23) from the adjacent component (1, 10, 16) to be produced, or The hollow body (9, 17) has a predetermined distance (23) from the at least one component (1) to be produced and from the outer edge of the virtual construction space.

5. A method according to any one of the preceding claims, wherein: Based on the temperature distribution in the virtual space (2) between the adjacent components (1, 10, 16) to be produced or between the at least one component (1) to be produced and the outer edge of the virtual construction space (2), the wall thickness (13) of the hollow body (9, 17) is adapted and taken into account when generating model data of the hollow body (9, 17).

6. A method according to any one of the preceding claims, wherein: The geometry of the hollow body (9, 17) is determined based on the temperature distribution between the adjacent components (1, 10, 16) to be produced in the virtual structural space (2) or between the outer edge of at least one component (1) to be produced and the virtual structural space (2) and the arrangement pattern (7), wherein this is taken into account when generating model data of the hollow body (9, 17).

7. A method according to any one of the preceding claims, wherein: As construction data, structural data, in particular CAD data, are provided, which indicate at which locations in the powder (5) thermal energy is introduced into the applied powder layer by a directed energy source (14) in order to selectively connect or melt the powder (5) at these locations.

8. A method for producing a component (1) using a powder bed based fusion method, comprising the following steps: - applying the powder (5) as a powder bed onto a support; - selectively applying heat to the powder (5) by means of a directed energy source (14) according to the construction data generated by the method according to any of the preceding claims; - removing the powder (5); as well as - Supplying reusable powder (5) as part of the removed powder (5) for the next manufacturing cycle.

9. A system (12) for producing a component (1) using a powder bed-based fusion method, comprising a memory unit (20), an evaluation unit (21) and an output unit (22), wherein: The system (12) is designed to carry out the steps of the method according to claim 8.

10. A computer program having commands which, when executed by a computer, cause the computer to carry out the method according to any one of claims 1 to 7, and which can be loaded into a memory unit (20) and can be executed by a processor.

Images