Method for producing a continuous surface area, irradiation device and processing machine

Abstract

Method for producing a continuous surface area (2) of a three-dimensional component (20) by irradiating a powder layer (3) by means of a processing beam (4), comprising: Moving the processing beam (4) along a plurality of stripes (S1, S2, ...) over the contiguous surface area (2), wherein in a respective stripe (S1, S2, ...) the contiguous surface area (2) is irradiated in a plurality of sub-areas (T1, T2) directly adjacent to one another along a respective stripe formation vector (H), and wherein a respective partial area (T1, T2) is scanned with the processing beam (4) in a scanning movement until the powder layer (3) in the respective partial area (T1, T2) is completely melted, characterized by that a first partial area (T1) of a respective strip (S1, S2, ...) is scanned by means of the processing beam (4) in a first scanning direction (R1) and immediately thereafter a second partial area (T2) of the strip (S1, S2, ...), which directly borders on the first partial area (T1) along a common edge (10), is scanned by means of the processing beam (4) in a second, is scanned from the first different scanning direction, in particular to the first vertical scanning direction (R2), or that first partial areas (T1) of a first strip (S1, S3, S5, S7, ...), which are directly adjacent to one another at points, are scanned by means of the processing beam (4) in a first scanning direction (R1), and that immediately following second partial areas (T2) of a second strip (S2, S4, S6, ...) immediately adjacent to the first, which are directly adjacent to one another at points, are scanned by means of the processing beam (4) in a second scanning direction (R2) which is different from the first and in particular perpendicular to the first.

Description

[0001] The present invention relates to methods for producing a continuous surface area of ​​a three-dimensional component by irradiating a powder layer using a processing beam, in particular using a laser beam or an electron beam. In one aspect of the invention, the method comprises: moving the processing beam along a plurality of strips over the continuous surface area, wherein in a respective strip the continuous surface area is irradiated in a plurality of directly adjacent partial areas, and wherein a respective partial area is scanned with the processing beam until the powder layer in the respective partial area is completely melted. The invention also relates to an irradiation device for a processing machine for producing three-dimensional components by irradiating powder layers.In one aspect of the invention, the irradiation device comprises a scanner device for aligning a processing beam onto a powder layer in a processing plane, a control device which is designed to control the scanner device to move the processing beam along a plurality of strips over the contiguous surface area in order to irradiate the contiguous surface area in a plurality of directly adjacent partial areas in a respective strip, and to control the scanner device to move the processing beam over a respective partial area in a scanning movement until the powder layer in the respective partial area has been completely melted.The invention also relates to a processing machine comprising: a processing chamber with a processing plane in which a powder layer to be irradiated can be arranged, and preferably a supply device for providing a gas stream that flows over the processing plane in a build platform area provided for providing a powder bed. In one aspect of the invention, the irradiation device is designed as described above.

[0002] Three-dimensional components can be manufactured using so-called generative manufacturing processes (also known as additive manufacturing processes). In such processes, the three-dimensional component is generated layer by layer. In so-called selective laser melting or laser sintering (also known as laser metal fusion, LMF), a powder material is locally melted by a high-energy processing beam, particularly a laser beam or an electron beam (in a vacuum, commonly referred to as electron beam melting, EBM), to create a layer of the three-dimensional component.

[0003] To create a contiguous surface area, it is necessary to completely scan (or rasterize) it or the surface to be melted using the processing beam. For this purpose, the contiguous surface area is usually divided into stripes or a checkerboard pattern with a plurality of square or rectangular sub-areas, as described, for example, in EP 2 956 262 B1. In both cases, it is necessary to process the generated polygon groups (consisting of a plurality of (scan) vectors) or sub-areas in a predetermined order. The order in which the sub-areas are processed has a significant influence on the quality of the manufactured component.

[0004] US 2019 / 0039318 A1 describes a method in which, to produce a cylindrical component, a powder layer is divided into a plurality of strips along which the powder material is melted by an energy source. Each strip can be irradiated in a plurality of directly adjacent, e.g., square, sub-regions. The sub-regions of a contiguous surface area can, for example, be arranged in a grid like checkerboard squares and can be scanned from top to bottom and from left to right. Alternatively, the order in which the sub-regions are irradiated can be randomized. The orientation of the strips can also vary from powder layer to powder layer in order to randomize the orientation of the scans used to produce the component.

[0005] WO 2019 / 016061 A1 discloses a method for generating a contiguous surface area, in which first sub-areas are scanned in a first scanning direction, while second sub-areas, which are immediately adjacent to the first sub-areas, are scanned along a second scanning direction, for example, perpendicular to the first scanning direction, in order to avoid the formation of preferred directions in the material of the component. The first and second sub-areas can be arranged in a checkerboard pattern. To generate the contiguous surface area, all first sub-areas can be processed first, followed by all second sub-areas.

[0006] With such an arrangement of first and second subregions in a checkerboard pattern, the irradiation of the first subregions can, for example, occur in a respective stripe along a stripe formation vector from right to left, and the stripes can be processed from top to bottom, omitting the second subregions. In a subsequent step, the second subregions can be processed accordingly, omitting the first, already exposed subregions.

[0007] Alternatively, to create the continuous surface area, it is possible to process the first sub-areas diagonally to the checkerboard pattern or grid, i.e., along a stripe formation direction that is oriented at a 45° angle to the grid. In this case, too, the second sub-areas are not exposed until the exposure of the first sub-areas is complete.

[0008] DE 100 42 134 C2 describes a method for producing three-dimensional workpieces in which specific individual sections are irradiated in a stochastic manner, one after the other, with the exception of consecutive irradiation of adjacent individual sections. WO 2008 / 074287 A1 also describes that individual sections irradiated one after the other must not be located directly next to one another.

[0009] The contiguous surface area or a surface area surrounded by an edge contour of the three-dimensional component can be created together with other contiguous surface areas of one and the same component or other components together from the powder layers of a powder bed arranged on a build platform (substrate plate) of an LMF processing machine. In this case, it is necessary to define a processing sequence for the contiguous surface areas.

[0010] EP 3 323 534 A1 discloses selecting the sequence of areas to be solidified in a respective powder layer depending on the flow direction of a gas stream passed over the powder layer. Here, the areas to be solidified in each powder layer are scanned in a sequence in which each area located downstream of another area in the flow direction of the gas stream is scanned before the other area. This is intended to prevent smoke or dirt generated during irradiation of the other area from accumulating in the area to be solidified.

[0011] To increase efficiency or build rate, two or more processing beams can be used to simultaneously process one or more contiguous areas of the same powder layer. In this case, too, it is necessary to establish a sequence in which the contiguous areas or sub-areas of the contiguous areas are processed.

[0012] Another alternative method for producing a continuous surface area of ​​a component by irradiating a powder layer using a processing beam is known from US 2016 / 0 001 401 A1. Object of the invention

[0013] The invention is based on the object of specifying a method of the type mentioned at the outset as well as an irradiation device and a processing machine with such an irradiation device, with which an efficient production of connected surface areas of three-dimensional components is possible without any loss of quality of the manufactured components. Subject of the invention

[0014] This object is achieved according to a first aspect by a method of the type mentioned at the outset, in which either a first partial area of ​​a respective strip is scanned by means of the processing beam in a first scanning direction along a respective strip formation vector and immediately thereafter a second partial area of ​​the strip, which directly borders the first partial area along a common edge, is scanned by means of the processing beam in a second scanning direction different from the first, in particular perpendicular to the first, or in which first partial areas of a first strip, which directly border one another at points, are scanned by means of the processing beam in a first scanning direction and immediately thereafter second partial areas of a second strip directly adjacent to the first, which directly border one another at points, are scanned in a second,from the first different scanning direction, in particular the first perpendicular scanning direction, by means of the processing beam.

[0015] As described above, when generating a contiguous surface area in which first partial areas are scanned in a scanning movement in a first scanning direction, while second partial areas which are immediately adjacent to the first partial areas are scanned in a scanning movement along a second scanning direction which is different from the first and in particular perpendicular to the first scanning direction, all of the first partial areas are generally irradiated first before the second partial areas are irradiated, or vice versa.

[0016] The inventor has recognized that this sequence of irradiating the subregions can be disadvantageous, particularly when creating comparatively large, contiguous surface areas, since the part of the surface area where irradiation of the first subregions began has already cooled down again by the time irradiation of the second subregions begins. To avoid this problem, it is proposed not to leave any longer pauses between the irradiation of a first subregion and an immediately adjacent second subregion.

[0017] In the first alternative described above, the term "immediately subsequent" means that no other sub-area of ​​the contiguous surface area is irradiated between the irradiation of the first sub-area and the irradiation of the second sub-area immediately adjacent to a common edge. Thus, in the first alternative, immediately adjacent first and second surface areas are exposed in immediate succession, which is contrary to the teachings described above that successively irradiated individual sections must not be located directly next to one another. The irradiation of immediately adjacent first and second sub-areas enables an increase in productivity, since no second sub-areas located between the first sub-areas need to be skipped, and vice versa.

[0018] In the second alternative described above, the term "immediately subsequently" means that after the first partial regions of the first strip have been irradiated, the second partial regions of the immediately adjacent second strip are exposed without other partial regions of the contiguous surface region being exposed in between. Point-adjacent surface regions are understood to mean that they do not border one another at a common edge, but rather at a common point of contact, for example at a corner. In the second alternative described above, the two immediately adjacent strips partially overlap. The mutual overlap of the adjacent strips can, for example, be approximately 50% of the width of the strips.

[0019] In both of the alternatives described above, a contiguous surface area of ​​the three-dimensional component is created or exposed, which is then divided (for example, in a preceding process step) into a plurality of first and second sub-areas. The plurality of (first and second) sub-areas typically forms a regular, grid-like arrangement, for example, in the manner of a checkerboard, which covers the contiguous surface area. Ideally, the sub-areas do not overlap and ideally border one another directly. Since the angles at which the processing beams strike the powder layer vary depending on the position in the processing area, an (unintentional) partial overlap of adjacent sub-areas may occur, usually no more than approximately 10% of the respective edge length (length or width) of the sub-areas.In the first alternative described above, the stripes and thus also the sub-areas overlap by a maximum of approx. 400 µm if the stripes are, for example, 4-8 mm wide.

[0020] In addition to the sub-areas, the stripes along which the contiguous surface area is traversed are defined (for example, in a preceding process step). For this purpose, it is necessary to specify a respective stripe formation vector. As a rule, the stripe formation vector is constant along a respective stripe, i.e., the stripes are straight. However, it is also possible for the stripe formation vector to vary depending on the position within a respective stripe. In this case, the stripe has a curvature, i.e., it deviates from a straight shape.

[0021] The term “scanning in a first / second scan direction” means that the processing beam is moved in a typically straight line along the (transverse) extent of the respective sub-area in the (positive and / or negative) scan direction. In this case, the processing beam can initially be moved in the (positive) scan direction from a first to an opposite second edge of the sub-area. At the second edge of the sub-area, a (slight) lateral offset of the processing beam takes place in a direction that is typically perpendicular to the scan direction. In addition, a reversal of movement of the processing beam can take place and the processing beam can be moved back in the (negative) scan direction in the opposite direction over the entire extent of the respective sub-area.Alternatively, the processing beam can be deactivated during movement toward the first edge, whereby the lateral offset of the processing beam can occur at the second edge or during movement of the (deactivated) processing beam in the (negative) scan direction. In particular, the processing beam can also be moved back and forth in an oscillating motion between the first edge and the second edge of the respective sub-area.

[0022] In one variant, the method comprises: moving the processing beam along a plurality of further strips of a further contiguous surface area of ​​a further powder layer of the three-dimensional component, which immediately follows the powder layer, wherein in a respective further strip the further contiguous surface area is irradiated in a plurality of immediately adjacent further partial areas, and wherein a respective further partial area is scanned with the processing beam in a scanning movement until the further powder layer in the respective further partial area has been completely melted, wherein a stripe formation vector when scanning the contiguous surface area along the plurality of strips and a further stripe formation vector when scanning the further contiguous surface area along the plurality of further strips form an angle of at least 45°, in particular of 90°,to each other. When determining the angle between the stripe formation vectors, the orientation of the vectors is taken into account, as is generally the case.

[0023] It has proven advantageous if the stripe formation vectors in powder layers directly following one another or arranged directly above one another in the powder bed are not aligned parallel to one another, but preferably form an angle of at least 45°, in particular 90°, to one another. In this way, residual stresses in the three-dimensional component to be produced can be homogenized, i.e., the distribution of residual stresses in the component is improved, and defects can be avoided.

[0024] In a further variant, a gas stream is guided over the powder layer, the flow vector of which forms an angle of at least 90°, preferably 135°, with a stripe formation vector when the processing beam moves along a respective stripe of the contiguous surface area and / or with a further stripe formation vector when the processing beam moves along a respective further stripe of the further contiguous surface area. In this case, the stripe formation vectors of the respective stripes generally have the same or a similar orientation, i.e., the stripe formation vectors of the respective stripes are, in particular, not aligned antiparallel to one another.

[0025] The gas flow can, for example, be a protective gas flow to protect optical components of an irradiation device, for example a window, from contamination, for example soot particles, which form during the irradiation of the powder material, as described in EP 3 023 228 A1. It has proven advantageous if the banding vector is at least partially directed opposite to the flow direction or the flow vector of the protective gas flow, since the protective gas flow removes soot particles or powder agglomerates which, in this case, would be deposited and welded onto the irradiated powder layer directly in front of the processing beam. An at least partially opposite banding vector is understood to mean that the banding vector and the flow vector of the gas flow are at an angle of more than 90° to one another, i.e.The banding vector has a non-zero component that runs antiparallel to the flow vector of the gas stream, as described in EP 2 956 262 B1. However, an orientation of the banding vector at 90° to the flow vector of the gas stream is also possible.

[0026] In addition to the stripe formation vector, it is advantageous if the (positive or negative) scanning direction is at least partially directed opposite to the flow vector of the gas flow, or if both vectors are aligned perpendicular to each other. This can be achieved if the scanning movement of the processing beam in a respective sub-area occurs with only one orientation, i.e., either in the positive or negative scanning direction. In this case, the (constant) scanning vector of the respective sub-area can enclose an angle of at least 90°, preferably more than 90°, with the flow vector of the gas flow.

[0027] According to the invention, a gas stream is guided over the powder layer, and the processing beam is guided along the plurality of stripes over the contiguous surface area in a sequence that depends on the sequence of the positions of the respective stripes along a flow vector of the gas stream. Stripes that are downstream in the sequence along the flow vector are processed before strips that are upstream in the sequence along the flow vector, i.e., the sequence of irradiation or processing of the stripes occurs against the flow direction or against the flow vector of the gas stream.

[0028] In a further aspect of the invention, which can in particular be combined with the aspect described above, all sub-regions of the contiguous surface area are processed in immediate succession using the processing beam. In this aspect of the invention, the entire contiguous surface area is (virtually) continuously irradiated by the processing beam until it is completely melted, i.e. if the exposure of the contiguous surface area begins with a temporally first sub-region, it is carried out to the end. The otherwise continuous irradiation is only briefly interrupted if necessary for the offset or movement of the laser beam when changing between different sub-regions.

[0029] In a further variant, the contiguous surface area is divided into a plurality of preferably rhomboid, in particular diamond-shaped, rectangular or square sub-areas. The geometry of the sub-areas into which the contiguous surface area is divided is generally uniform. The choice of polygonal, in particular rhomboid sub-areas allows neighboring sub-areas to adjoin one another along (at least) one common edge. The use of square sub-areas in particular has proven advantageous. In addition to the geometry, the area of ​​the respective sub-areas that form the contiguous surface area is also generally the same size. However, it is also possible for the contiguous surface area to have several types of, for example, rectangular sub-areas that differ in their area, for example in their width and / or length.The use of smaller sub-areas can be particularly advantageous at the edge of the contiguous surface area in order to adapt it as well as possible to a surrounding edge contour.

[0030] In a further variant, the contiguous surface area is surrounded by an edge contour of the three-dimensional component, wherein the edge contour and / or an edge region formed between the edge contour and the contiguous surface area is / are irradiated with the processing beam or with at least one further processing beam. As a rule, the edge contour of the three-dimensional component to be produced does not correspond to the edge contour of the contiguous surface area within the respective powder layer, so that an edge region remains between the edge contour and the contiguous surface area. The edge region typically has a geometry or a surface into which no part of the contiguous surface area fits. The edge region is therefore typically irradiated or melted with a single processing beam.For this purpose, the processing beam can be used, or another processing beam can be used, which is generated by another beam source and / or which is directed onto the powder layer via another scanner device.

[0031] A further aspect of the invention relates to a method for producing a continuous surface area of ​​a three-dimensional component by irradiating a powder layer with at least one processing beam, wherein in particular at least one further continuous surface area has at least one section which is arranged downstream of at least one section of the continuous surface area with respect to a flow vector of a gas flow guided over the powder layer and which overlaps with the section of the continuous surface area transversely to the flow vector, the method comprising: irradiating the continuous surface area with at least one processing beam in at least one of a plurality of sub-areas into which the continuous surface area is divided, until the powder layer in the at least one sub-area is completely melted,wherein the irradiation of the partial areas is repeated immediately one after the other until all partial areas of the contiguous surface area have been completely melted.

[0032] In this aspect of the invention, it is proposed to deliberately deviate from a processing sequence in which contiguous surface areas or sub-areas that are located downstream of other contiguous surface areas with respect to the flow vector of the gas flow are irradiated first. If this processing sequence were maintained, after the start of exposure of a contiguous surface area that extends at least in a section upstream of another contiguous surface area and overlaps with a downstream section of the further contiguous surface area, the irradiation of the contiguous surface area would have to be interrupted in order to expose the surface portion of the further contiguous surface area that is downstream with respect to the flow vector.

[0033] This aspect of the invention proposes continuing irradiation of a contiguous surface area whose irradiation has begun without interruption until the contiguous surface area has been completely irradiated, regardless of whether or where further contiguous surface areas are arranged in the powder layer. This ensures that the contiguous surface area cannot cool down in the meantime. This prevents the solidified material from contracting and creating a gap. Furthermore, the cooling requires more energy to remelt the solidified material in order to bond it to the next sub-area when irradiation is resumed.

[0034] In one variant, at least two of the majority of sub-areas of the contiguous surface area are irradiated simultaneously with at least two processing beams. The above rule also applies if two or more processing beams are used for irradiation. In this case, two or more processing beams can irradiate the same contiguous surface area in parallel—at least temporarily. The exposure of the contiguous surface area does not have to be continuous with two or more processing beams; however, at least one processing beam always irradiates the sub-areas of the contiguous surface area until its irradiation is complete.

[0035] When irradiating two sections simultaneously, it should be noted that two directly adjacent sections should generally not be treated simultaneously with two treatment beams, at least not if one section is located downstream of the second section along the gas flow vector and both sections overlap at least partially transversely to the flow vector. Otherwise, the smoke from one treatment beam can enter the beam path of the other treatment beam and obscure it or lead to diffuse deflection or scattering of the other treatment beam, which negatively affects the beam quality. Furthermore, local overheating may occur in this case.

[0036] In a further variant, the contiguous surface area extends further downstream with respect to the flow vector of the gas flow than at least one other contiguous surface area, and the irradiation of the contiguous surface area begins before the irradiation of the further contiguous surface area. The order in which the contiguous surface areas are irradiated depends on their extension along the flow direction or the flow vector of the gas flow. As a rule, the contiguous surface area that extends furthest downstream is irradiated first. The other contiguous surface areas are irradiated in the order of their maximum extension along the flow vector of the gas flow.

[0037] In a further variant, a first processing beam begins irradiating the (first) contiguous surface area, and a second processing beam either irradiates the (first) contiguous surface area together with the first processing beam, or the second processing beam begins irradiating another (second) contiguous surface area that extends second furthest downstream. If a third processing beam is available, it can support the first or second processing beam, i.e., irradiate the first or second contiguous surface area together with the first processing beam. Alternatively, the third processing beam can begin irradiating a third surface area that extends third furthest downstream, and so on.

[0038] When a contiguous surface area is irradiated together, different sub-areas are irradiated by different processing beams. If a contiguous surface area is irradiated in multiple stripes, as described above, each strip is typically irradiated with only one processing beam, i.e., different processing beams operate in different stripes.

[0039] In a further development, if the first and second processing beams interfere with each other when jointly irradiating the contiguous surface area, the first or second processing beam immediately subsequently begins irradiating another contiguous surface area or immediately subsequently irradiates another contiguous surface area together with a third processing beam.

[0040] Depending on the geometry of the contiguous surface area, it may occur that the two processing beams interfere with each other during joint irradiation, for example, because the sub-areas to be irradiated simultaneously are adjacent to each other or overlap in the direction of the gas flow. In this case, one of the processing beams can begin irradiating a new contiguous surface area or support a third processing beam. Once a processing beam has switched to another contiguous surface area, the same processing beam should generally not return to the originally irradiated contiguous surface area.In the event that two or more processing beams interfere with each other when irradiating the other surface area, a processing beam that has changed the contiguous surface area should start irradiating a part of a new contiguous surface area.

[0041] It is understood that after the end of the exposure of one contiguous surface area, a processing beam immediately switches to another contiguous surface area in order to irradiate this (if necessary with a different processing beam). As a rule, a processing beam that has finished exposing a contiguous surface area will support another processing beam in another contiguous surface area, i.e. it will irradiate the other contiguous surface area together with the other processing beam. The other contiguous surface area can in particular be the first contiguous surface area. If this is not possible because the processing beams obstruct each other, the processing beam begins by irradiating a new, not yet irradiated contiguous surface area.In this way, waiting times can be avoided and productivity in the production of three-dimensional components can be increased while at the same time ensuring good component quality.

[0042] In a further variant, the further contiguous surface area, at least in the section located downstream of the section of the contiguous surface area, is not irradiated at the same time as the overlapping section of the contiguous surface area. This prevents a processing beam irradiating the further contiguous surface area in the downstream section from being obstructed by smoke generated during the irradiation of the upstream section of the further surface area. In particular, it is possible for the irradiation of the further contiguous surface area to begin only when the irradiation of the contiguous surface area is completely finished.

[0043] The invention also relates to an irradiation device of the type mentioned at the outset, in which the control device is designed or programmed to control the scanner device, to scan a first partial area of ​​a respective strip by means of the processing beam in a first scanning direction and immediately thereafter to scan a second partial area of ​​the strip, which directly borders the first partial area along a common edge, by means of the processing beam in a second scanning direction different from the first, in particular perpendicular to the first scanning direction, or in which the control device is designed to control the scanner device, to scan first partial areas of a first strip, which directly border one another at points, by means of the processing beam in a first scanning direction and immediately thereafter to scan second,to scan directly adjacent partial areas of a second strip immediately adjacent to the first in a second scanning direction different from the first, in particular perpendicular to the first scanning direction, by means of the processing beam.

[0044] The control device is thus designed or programmed to carry out the first method described above for generating the contiguous surface area. Accordingly, the control device can also be designed or programmed to carry out the variants of the first method described above. For this purpose, the control device acts on the (at least one) scanner device, more precisely on one or more scanner mirrors of the scanner device. It is possible for the irradiation device to have a single scanner device. However, the irradiation device can also have two or more, usually identically constructed, scanner devices that are arranged such that their scanning areas or processing fields overlap in the processing plane.

[0045] It is understood that the irradiation device described above or a processing machine comprising the irradiation device can have at least one beam source, in particular at least one laser source, for generating the at least one processing beam or laser beam. In particular, laser sources with a power in the range of more than 100 W can be used.

[0046] A further aspect of the invention relates to a processing machine of the type mentioned at the outset, which has an irradiation device designed as described above. The processing machine can, for example, be designed as described in EP 3 023 228 A1, which is incorporated in its entirety by reference into this application. A production space is provided in the processing chamber, in which a work surface is typically arranged at the level of the processing plane. The processing region of the irradiation device is formed in a part of the work surface in which a build platform region is provided for providing a powder bed, the uppermost powder layer of which lies in the processing plane. A powder reservoir region with a powder storage container can be provided in the processing chamber for providing the powder.A sliding device arranged in the processing chamber can be used to transfer the powder from the powder reservoir to the build platform area. The gas flow can be used to remove smoke from the processing chamber, as described in EP 3 023 228 A1. The supply device (gas system) used to provide the gas flow can be designed, for example, as described in EP 3 023 228 A1.

[0047] A further aspect of the invention relates to a processing machine of the type mentioned above, further comprising: an irradiation device having at least one scanner device for aligning at least one processing beam onto the powder layer in the processing plane, and a control device configured to control the at least one scanner device to irradiate a contiguous surface area with at least one processing beam in at least one of a plurality of sub-areas into which the contiguous surface area is divided, until the powder layer in the at least one sub-area is completely melted, and wherein the control device is configured to control the at least one scanner device to repeat the irradiation of the sub-areas in immediate succession until all sub-areas of the contiguous surface area are completely melted,wherein, in particular, at least one further contiguous surface area has at least one section which, with respect to a flow vector of a gas flow guided over the powder layer, is arranged downstream of at least one section of the contiguous surface area and which overlaps the section of the contiguous surface area transversely to the flow vector.

[0048] The control device is thus designed or programmed to execute the second method described above for generating the contiguous surface area. Accordingly, the control device can also be designed or programmed to execute the variants of this method described above. For this purpose, the control device acts on the at least one scanner device, more precisely on one or more scanner mirrors of the at least one scanner device, and generally on the beam source(s) for generating the processing beams.

[0049] In one embodiment, the contiguous surface area extends further downstream with respect to the flow vector of the gas flow than at least one other contiguous surface area, and the control device is configured to control the scanner device to begin irradiating the contiguous surface area before irradiating the other contiguous surface area. As described above, the order of generating the contiguous surface areas is preferably determined depending on the sequence of the contiguous surface areas along the flow direction of the gas flow.

[0050] In a further embodiment, the control device is configured to control the scanner device, to begin irradiating the contiguous surface area with a first processing beam, and to begin irradiating the contiguous surface area with a second processing beam, either together with the first processing beam, or to begin irradiating another contiguous surface area. In this way, waiting times can be avoided and productivity in the production of three-dimensional components can be increased.

[0051] In a further development, if the first and second processing beams interfere with each other during the joint irradiation of the contiguous surface area, the control device controls the scanner device to immediately begin irradiating another contiguous surface area with the first or second processing beam, or to immediately subsequently irradiate another contiguous surface area together with a third processing beam. In this way, the productivity of the processing machine can also be increased during the parallel production of multiple three-dimensional components.

[0052] In a further embodiment, the control device is configured to control the at least one scanner device so that the further contiguous surface area is not irradiated simultaneously with the overlapping section of the contiguous surface area, at least in the section located downstream of the section of the contiguous surface area. In particular, the control device can be configured not to irradiate the contiguous surface area and the further contiguous surface area having the at least one overlapping section at the same time, or to begin irradiating the further contiguous surface area only when the irradiation of the contiguous surface area is complete.

[0053] Further advantages of the invention will become apparent from the description and the drawings. Likewise, the features mentioned above and those listed below can be used individually or in combinations. The embodiments shown and described are not intended to be exhaustive, but rather are exemplary in nature for describing the invention.

[0054] They show: Fig. 1 a schematic representation of an irradiation device with a scanner device for aligning a processing beam onto a powder bed, Fig. 2 a schematic representation of a processing machine for producing three-dimensional components by irradiating powder layers with the irradiation device according to Fig. 1, Fig. 3a,b are schematic representations of a continuous surface area with a plurality of stripes along which the processing beam is moved in order to irradiate immediately successive adjacent first and second partial areas, Fig. 4 a schematic representation analogous to Fig. 3a,b, in which first partial areas adjacent to one another at points are irradiated in a first strip and immediately thereafter second partial areas adjacent to one another at points are irradiated in a second strip, Fig. 5 a schematic representation of a processing machine with an irradiation device with three scanner devices for aligning three laser beams onto a powder layer in a processing plane, and Fig. 6a-d schematic representations of the irradiation of several connected surface areas of the powder layer using the three laser beams.

[0055] Fig. Figure 1 shows an irradiation device 1, which serves to irradiate a continuous surface area 2 of a powder layer 3, which in the example shown is rectangular. For the irradiation, the irradiation device 1 is guided by a Fig. 1, a processing beam 4 in the form of a laser beam is fed to a beam source (not shown in the figure). The irradiation device 1 has a scanner device 5 with two rotatable scanner mirrors 6a, 6b (galvano mirrors), which serve to deflect or align the processing beam 4 into a processing plane E in which the powder layer 3 is arranged. In the example shown, the processing plane E lies in the XY plane of the XYZ coordinate system.

[0056] As in Fig. 1, a focusing device 7 in the form of a focusing lens is arranged in the beam path of the processing beam 4 in order to focus the processing beam 4 in the processing plane E. A focus position correction device (not shown) can also be arranged in the beam path of the processing beam 4, which serves for the (dynamic) correction of the focus position of the processing beam 4 (in the beam direction) in order to ensure that the focus position as in Fig. 1 is shown in the processing plane E.

[0057] The Fig. The contiguous surface area 2 shown in Figure 1 is surrounded by an edge contour 8, which corresponds to the outer contour of a layer of the three-dimensional component that is to be created during the irradiation of the powder layer 3. To produce the three-dimensional component, the entire area within the edge contour 8 is to be irradiated. In the example shown, the area within the edge contour 8 is divided into the contiguous rectangular surface area 2 and an edge region 9, which is formed between the contiguous surface area 2 and the edge contour 8. The contiguous surface area 2 is irradiated by moving the processing beam 4 along three strips S1, S2, S3 aligned parallel to one another, as described in more detail below. The edge region 9 and the edge contour 8, on the other hand, are not irradiated with the processing beam 4 in strips, but in any other way, which is fundamentally arbitrary.

[0058] Each of the three strips S1, S2, S3 has a total of eight square sub-areas, of which two adjacent sub-areas T1, T2, ... are directly adjacent to one another along a straight edge 10 extending in the longitudinal direction of the continuous surface area 2. The sub-areas T1, T2, ... have a length in the longitudinal and transverse direction of the continuous surface area 2, which can be, for example, approximately 3-8 mm. Unlike in Fig. 1, the sub-areas T1, T2, ... can have a rectangular, rhomboid, diamond-shaped or basically any geometry, provided that they can be arranged in a regular arrangement in the manner of a grid or a matrix.

[0059] To irradiate a respective partial area T1, T2, ..., the position of the processing beam 4 in the processing plane E is changed with the aid of the scanner device 5 until the powder layer 3 in the respective partial area T1, T2, ... has completely melted. In the example shown, when the position of the processing beam 4 is changed, the first partial area T1 is scanned in a first scanning direction R1, which corresponds to the longitudinal direction of the contiguous surface area 2. The processing beam 4 is moved over the entire length of the first partial area T1, with a reversal of movement taking place at the edge of the first partial area T1 together with a slight lateral offset in order to form an adjacent path or track along the scanning direction R1, until the first partial area T1 is completely melted, i.e. over its entire area.During the scanning movement, the processing beam 4 is thus moved in both the positive and negative scanning direction R1, as shown in . Fig. 1 is indicated by a double arrow.

[0060] Accordingly, the second partial area T2 is also scanned by the processing beam 4, but in a second scanning direction R2, which runs in the transverse direction of the contiguous surface area 2 and thus perpendicular to the first scanning direction R1. In this case, the processing beam 4 is also moved in both the positive and negative second scanning direction R2 during the scanning movement, as in Fig. 1 is indicated by a double arrow.

[0061] As in Fig. 1, first sub-areas T1 alternate with second sub-areas T2 in a respective strip S1, S2, S3. The order of the sub-areas T1, T2 in adjacent strips S1, S2; S2, S3 also alternates, so that the first and second sub-areas T1, T2 cover the contiguous surface area 2 in a checkerboard pattern when the processing beam 4 has traversed all three strips S1, S2, S3 and thus all first and second sub-areas T1, T2 of the contiguous surface area 2.

[0062] In a step preceding or following the creation of the continuous surface area 2, the edge area 9 and the edge contour 8 can be irradiated with the processing beam 4 in order to completely irradiate the area located within the edge contour 8. In the example shown, the movements of the scanner mirrors 6a, 6b are coordinated by means of a Fig. 2 shown control device 11 of the irradiation device 1.

[0063] The orientation of the longitudinal direction and the transverse direction of the connected surface area 2 in the processing plane E is basically arbitrary. In the example shown, the longitudinal direction and the transverse direction of the connected surface area 2 are aligned at an angle of -45° and 45°, respectively, with respect to a flow vector G of a shielding gas flow 13, which is guided over the powder layer 3. The shielding gas flow 13 is generated by a supply device 14 (gas system) which is Fig. 1 is indicated by dashed lines and runs in the (positive) Y direction of the XYZ coordinate system. Alternatively to providing a shielding gas flow 13 having a flow vector G in the positive Y direction, the shielding gas flow 13 may have a flow vector in the positive or negative X direction or be oriented in a different way.

[0064] The protective gas flow 13 is in a processing chamber 16 of a Fig. 2 is guided over the powder layer 3, which forms the uppermost layer of a powder bed 19 in which a three-dimensional component 20, or more precisely, the already produced layers of the three-dimensional component 20, are embedded. The powder bed 19 is formed in a construction platform area 17, which has, for example, a cylindrical construction platform with a stamp, on the upper side of which the processing plane E is formed, which is irradiated by the irradiation device 1 in the manner described above. The processing machine 15 also has a beam source 23 in the form of a laser source for generating the processing beam 4.

[0065] The protective gas flow 13 is guided over the build platform area 17 in order to keep smoke away from the irradiation device 1 arranged above it, for example from a window formed there. The supply device 14 can be designed, for example, as in EP 3 023 228 A1 cited at the beginning. In order to ensure that the flow direction or the flow vector G of the protective gas flow 13 (here: positive Y direction) is at least partially directed opposite the direction of movement of the processing beam 4 in the processing plane E, the exposure of the partial areas T1, T2 can take place by moving the processing beam 4 with only one orientation over the respective partial area T1, T2, ie, for example, only in the positive scanning direction R1, R2, ie the opposite movement along the negative scanning direction R1, R2 (or vice versa) is omitted.

[0066] In the Fig. 1, the processing beam 4 is guided along the three strips S1, S2, S3 in an order over the contiguous surface area which depends on the sequence of the respective strips S1, S2, S3 along the flow vector G of the gas flow 13. The order of irradiation of the three strips S1, S2, S3 is counter to the flow vector G of the gas flow 13: First, the first strip S1 is irradiated, which is furthest downstream in the flow direction G of the gas flow 13, then the second strip S2, which is second furthest downstream in the flow direction G, and then the third strip S3 is irradiated, which is third furthest downstream in the flow direction G.

[0067] Equivalently, the order of irradiation of the three strips S1, S2, S3 can be selected depending on the distance of the respective strip S1, S2, S3 along the flow vector G from the provision device 21. In this case, strips S1, S2, ..., which are at a greater distance from the provision device 14 in the flow direction G, are irradiated before strips S1, S2, ..., which are at a shorter distance from the provision device 14 in the flow direction G. The distance between a respective strip S1, S2, S3 and the provision device 21 or the sequence along the flow vector G is defined by the sub-region T1, T2 of the respective strip S1, S2, S3 that is furthest away along the flow vector G or the furthest point of the respective sub-region T1, T2.

[0068] To create a new layer of the three-dimensional component 20, powder is first taken from a powder reservoir container 22 arranged in the processing chamber 16 and transferred from a powder reservoir area 18, in which the powder reservoir container 22 is located, to the build platform area 17. In the example shown, a sliding device (not shown in detail) is used for this purpose, which transfers the powder from the powder reservoir area 18 to the build platform area 17 by displacing the powder on the upper side of a work surface located in the processing plane E. A stamp 21 in the build platform area 17 and thus the powder bed 19 is displaced downwards in parallel by the layer thickness of a powder layer, as shown in Fig. 2 is indicated by an arrow before the irradiation of the (new) powder layer 3 in the build platform area 17 is carried out.

[0069] A processing area B for carrying out the irradiation of the powder layer 3 is delimited laterally by the build cylinder of the build platform area 17. The dimensions of the processing area B, which can be approximately 30 cm, for example, are adapted to the (maximum) deflection angle α of the processing beam 4 by the scanner device 5, i.e. the scanner mirrors 6a, 6b can be rotated about their respective axes of rotation to such an extent that every location of the processing area B in the processing plane E can be reached.

[0070] Fig. 3a shows a square connected area 2 of the Fig. 2 shown component 20 with the in Fig. 1 shown checkerboard arrangement of the first and second sub-areas T1, T2. As this is related to Fig. 1, the irradiation of the continuous surface area 2 takes place along a plurality of strips, of which Fig. 3a, a first to sixth strip S1, ..., S6 are shown by way of example. The respective strips S1, ..., S6 are traversed by means of the processing beam 4 along a respective strip formation vector H, which has the same direction and orientation for all strips S1, ..., S6. As shown in Fig. 3a, the flow vector G of the gas stream 13 forms an angle α of 135° with the stripe formation vector H, ie the stripe formation vector H has a component other than zero, which is directed opposite to the flow vector G. The irradiation of the partial areas T1, T2 of the respective stripes S1, ..., S6 takes place in Fig. 3a in the order shown as an example for the sixth strip S6 (1st to 13th), ie first and second partial areas T1, T2 which are immediately adjacent to one another at a common edge 10 are traversed in immediate succession by means of the processing beam 4 in a scanning movement.

[0071] Fig. 3b shows a further continuous surface area 2' of a further powder layer 3' of the three-dimensional component 20, which is directly applied to the Fig. 2 shown powder layer 3 is applied. The further contiguous surface area 2' and the contiguous surface area 2 have an identical size and are positioned at the same location within the processing area B. The irradiation of the further contiguous surface area 2' takes place analogously to the irradiation of the contiguous surface area 2, ie the processing beam 4 is moved along a number of further strips S1', ... S6', which each have further first and second partial areas T1', T2', which are scanned in scanning directions R1, R2 that are perpendicular to one another.

[0072] Also during the irradiation of the further contiguous surface area 2', further partial areas T1', T2' directly adjacent to one another at a common edge 10 are scanned in direct succession by means of the processing beam 4 in a scanning movement, as shown in Fig. 3b (1 to 13). The further stripes S1', ..., S6' are traversed along a further stripe formation direction H' by means of the processing beam 4, which forms an angle θ of 90° to the stripe formation direction H of the powder layer 3 of Fig. 3a. This is beneficial for reducing residual stresses in the three-dimensional component 20. As shown in Fig. 3a is the further stripe formation direction H' of Fig. 3b is aligned at an angle α of 135° to the flow vector G of the gas stream 13.

[0073] Fig. 4 shows the connected area 2 of Fig. 3a, in which an alternative type of exposure of the first and second partial areas T1, T2 is carried out. In the Fig. 4, the processing beam 4 is guided along a plurality of strips S1, ..., S7 over the continuous surface area 2, namely in the direction shown in Fig. 4 shown order (1st to 7th). Unlike in Fig. As shown in Figure 3a, the banding vector H runs in Fig. 4 at an angle α of 90° to the flow vector G of the gas stream 13 (in (positive) X-direction). Fig. 4, first partial areas of a first strip S1, S3, S5, S7, ..., which are directly adjacent to one another at a respective corner, are scanned by means of the processing beam 4 along a first scanning direction R1, ie the first partial areas T1 in Fig. 4 are processed from left to right. Immediately following, in a directly adjacent second strip S2, S4, S6, ..., second partial areas T2, which also adjoin each other at a common corner, are scanned in a second scanning direction R2 perpendicular to the first. Fig. In the irradiation of the contiguous surface area 2 shown in Figure 4, adjacent strips S1, S2, ... overlap by 50% of their width.

[0074] Fig. 5 shows a processing machine 15 which differs from the one shown in Fig. 2 essentially by the design of the irradiation device 1, and in that the processing machine 15 has three beam sources 23a, 23b, 23c instead of a single beam source 23. The first beam source 23a generates a first processing beam 4a, which is aligned with the processing plane E or deflected in the direction of the processing plane E via a first scanner device 5a. The second beam source 23b generates a further (second) processing beam 4b, which is aligned with the processing plane E via a further (second) scanner device 25b. The third beam source 23c generates a further (third) processing beam 4c, which is aligned with the processing plane E via a third scanner device 5c. The representation of further optical elements of the irradiation device 1, which, for example, as in the Fig. 1 shown irradiation device 1 can be designed, was described in Fig. 5 has been omitted for reasons of clarity.

[0075] At the Fig. In the irradiation device 1 shown in Figure 5, a telecentric F-Theta lens 27 is used to focus the three processing beams 4a-c in the processing plane E. Due to the telecentricity, the processing beams 4a-c always strike the processing plane E perpendicularly, regardless of their location on the processing field. It is understood that a (telecentric) F-Theta lens 27 is also used in the irradiation device shown in Figure 5. Fig. 1 can be used.

[0076] The following is based on Fig. 6a-d describe the generation of four contiguous surface areas F1 to F4 in one and the same powder layer 3 using the three processing beams 4a-c. A processing sequence or an assignment of the processing beams 4a-c to the respective contiguous surface areas F1 to F4 is performed, which utilizes the processing beams 4a-c to the greatest possible capacity while simultaneously ensuring good quality of the component 20 to be manufactured. The surface areas F1 to F4 can be assigned to one and the same component 20, but it is also possible for the surface areas F1 to F4 to be assigned to different components 20 that are manufactured simultaneously in the powder bed 19.

[0077] In principle, the production of a respective contiguous surface region F1 to F4, for example the first surface region F1, proceeds as follows: The (contiguous) first surface region F1 is irradiated with at least one processing beam 4a-c in at least one of a plurality of partial regions T1, ..., Tn into which the first surface region F1 is divided, until the powder layer 3 in the at least one partial region T1, ..., Tn is completely melted. The irradiation of the partial regions T1, ..., Tn is repeated in immediate succession until all partial regions T1, ..., Tn of the first surface region F1 are completely melted.In other words, after irradiating a temporally first partial region T1, the first contiguous surface area F1 is (quasi) continuously irradiated with at least one of the three processing beams 4a-c until the powder layer 3 in the first surface area F1 is completely melted, i.e., until the last partial region Tn is melted, so that the irradiation of the first surface area F1 is completed. The irradiation of the first surface area F1 with at least one of the three processing beams 4a-c is only interrupted in order to move a respective processing beam 4a-c to a respective different partial region T1, ..., Tn, wherein the processing beam 4a-c or the corresponding beam source 23a-c is deactivated during this movement.

[0078] At least part of the irradiation of the first surface area F1 can be carried out with the aid of two or, if appropriate, three of the processing beams 4a-c simultaneously, wherein the processing beams 4a-c each irradiate different sub-areas T1, ..., Tn of the first surface area F1. The irradiation in the respective sub-areas T1, ..., Tn can take place in the manner described above, i.e. in a scanning movement along a respective first or second scanning direction R1, R2 perpendicular to the first. The sub-areas T1, ..., Tn can be arranged in a checkerboard-like grid and form the first and second sub-areas T1, T2 described above, which are scanned in different scanning directions R1, R2. Immediately adjacent sub-areas T1, T2, ... can, for example, be scanned with mutually perpendicular scanning directions R1, R2, but this is not absolutely necessary.

[0079] As in Fig. 6a-d, the fourth surface area F4 is arranged partially downstream of the first surface area F1 with respect to the flow vector G of the gas flow 13 guided over the powder layer 3, specifically in a (middle) section A4 which overlaps transversely to the flow vector G with an upstream section A1 of the first surface area F1. In the following with reference to Fig. In the example explained in Figures 6a-d, the irradiation of the first surface region F1 is completed before the irradiation of the fourth surface region F4 begins. It may also be possible to begin the irradiation of the fourth surface region F4 before the irradiation of the first surface region F1 is completely completed. In this case, care must be taken to coordinate the irradiation so that the downstream section A4 of the fourth surface region F4 is not irradiated at the same time as the overlapping section A1 of the first surface region F1. In any case, once the irradiation of the first surface region F1 has begun, it is not interrupted until it has completely melted.

[0080] Fig. Figure 6a shows the irradiation at a time when the first processing beam 4a has begun irradiating the first surface area F1. Parallel to the irradiation of the first surface area F1 with the first processing beam 4a, the second surface area F2 is irradiated with the second processing beam 4b. The third processing beam 4c serves to expose the edge contour 8 of the fourth surface area F4.

[0081] After the end of the exposure of the edge contour 8 of the fourth surface area F4, the second processing beam 4b briefly exposes the first surface area F1 together with the first processing beam 4a. Fig. At the time shown in Figure 6b, the first and second processing beams 4a, 4b interfered with each other during the joint irradiation of the first surface area F1, which is why the first processing beam 4a irradiates the second surface area F2 together with the third processing beam 4c. If no suitable partial area T1, ..., Tn is available for irradiation in the second surface area F2, the first processing beam 4a could alternatively begin irradiating the third surface area F3 immediately thereafter.The prerequisite for this is that the third processing beam 4c, when exposing the third surface area F3, does not influence the exposure of the second surface area F2 by the first processing beam 4a by a smoke cloud which, along the flow vector G of the gas flow 13, reaches a section of the second surface area F2 which overlaps the third surface area F3 transversely to the flow vector G.

[0082] Fig. Figure 6c shows the irradiation at a time when the second processing beam 4b has further exposed the first surface area F1 and when the first and third processing beams 4a, 4c have completed the irradiation of the second surface area F2. As in Fig. As shown in Figure 6d, the first and third processing beams 4a, 4c assist the second processing beam 4b in exposing the first surface area F1 until it is fully exposed. One of the three processing beams 4a-c subsequently begins exposing the third surface area F3 (not shown).

[0083] The order in which the irradiation of the four surface areas F1 to F4 is started depends on the maximum extension of the surface areas F1 to F4 along the Y-direction in which the flow vector G of the gas stream 13 in the Fig. 6a-d. The edge of the first surface region F1 facing away from the provision device 14 in the Y direction has the greatest extent in the Y direction and thus the greatest distance in the Y direction from the provision device 14. The irradiation of the first surface region F1 is therefore started first. The second surface region F2 extends somewhat further in the Y direction than the third surface region F3, so that the irradiation of the second surface region F2 begins before the irradiation of the third surface region F3. The fourth surface region F4 extends the shortest way in the Y direction with its edge facing away from the provision device 14 and the irradiation is therefore started last of the four surface regions F1 to F4. The fourth surface region F4 also has a section that is arranged upstream of a section of the first surface region F1. It is therefore possible orIt is advantageous to start the irradiation of the fourth surface area F4 only when the irradiation of the first surface area F1 has been completely completed.

[0084] For the movement of the processing beams 4a-c over the processing area B, the control device 11 of the irradiation device 1 controls the three scanner devices 4a-c so that they carry out the irradiation of the surface areas F1 to F4 in the desired sequence. For this purpose, a processing program can be stored in the control device 11, which can be designed in the form of suitable hardware and / or software. The processing program is typically created in advance based on the geometry of the component(s) 20 to be manufactured and processed by the control device 11. The control device 11 also controls the beam sources 23a-c in order to switch them on and off at suitable times. The same applies to the control device 11 of the Fig. 2 shown processing machine 1, which controls the scanner device 5 or the beam source 23 in a suitable manner.

[0085] It is understood that the irradiation of the respective sub-areas T1, ..., Tn of the surface areas F1 to F2 of Fig. 6a-d does not necessarily have to be carried out in a scanning movement, but that the pattern used for irradiating a respective partial area T1, ..., Tn is basically arbitrary, even if a scanning movement is usually advantageous.

Claims

[1] Method for producing a continuous surface area (2) of a three-dimensional component (20) by irradiating a powder layer (3) by means of a processing beam (4), comprising: Moving the processing beam (4) along a plurality of stripes (S1, S2, ...) over the contiguous surface area (2), wherein in a respective stripe (S1, S2, ...) the contiguous surface area (2) is irradiated in a plurality of sub-areas (T1, T2) directly adjacent to one another along a respective stripe formation vector (H), and wherein a respective partial area (T1, T2) is scanned with the processing beam (4) in a scanning movement until the powder layer (3) in the respective partial area (T1, T2) is completely melted, characterized by , that a first partial area (T1) of a respective strip (S1, S2, ...) is scanned by means of the processing beam (4) in a first scanning direction (R1) and immediately thereafter a second partial area (T2) of the strip (S1, S2, ...), which directly borders on the first partial area (T1) along a common edge (10), is scanned by means of the processing beam (4) in a second, is scanned from the first different scanning direction, in particular to the first vertical scanning direction (R2), or that first partial areas (T1) of a first strip (S1, S3, S5, S7, ...), which are directly adjacent to one another at points, are scanned by means of the processing beam (4) in a first scanning direction (R1), and that immediately following second partial areas (T2) of a second strip (S2, S4, S6, ...) immediately adjacent to the first, which are directly adjacent to one another at points, are scanned by means of the processing beam (4) in a second scanning direction (R2) which is different from the first and in particular perpendicular to the first. [2] The method of claim 1, further comprising: Moving the processing beam (4) along a plurality of further strips (S1', S2', ...) of a further contiguous surface area (2'), a further powder layer (3') of the three-dimensional component (20), which immediately follows the powder layer (3), wherein in a respective further strip (S1', S2', ...) the further contiguous surface area (2') is irradiated in a plurality of immediately adjacent further partial areas (T1', T2'), and wherein a respective further partial area (T1', T2') is scanned with the processing beam (4) in a scanning movement until the further powder layer (3') in the respective further partial area (T1', T2') is completely melted, wherein a stripe formation vector (H) when traversing the contiguous surface area (2) along the plurality of stripes (S1, S2, ...) and a further stripe formation vector (H') when traversing the further contiguous surface area (2') along the plurality of further stripes (S1', S2', ...) have an angle (θ) of at least 45°, in particular of 90°, to one another. [3] Method according to claim 1 or 2, in which a gas stream (13) is guided over the powder layer (3), the flow vector (G) of which has an angle (α) of at least 90°, preferably of 135°, with a stripe formation vector (H) when the processing beam (4) moves along a respective stripe (S1, S2, ...) of the continuous surface area (2) and / or with a further stripe formation vector (H') when the processing beam (4) moves along a respective further stripe (S1', S2', ...) of the further continuous surface area (2'). [4] Method according to one of the preceding claims, in which a gas stream (13) is guided over the powder layer (3), the processing beam (4) being guided along the plurality of strips (S1, S2, ...) in an order over the continuous surface area (2) which is dependent on the sequence of the respective strips (2) along a flow vector (G) of the gas stream (13). [5] Method according to one of the preceding claims, in which all partial areas (T1, T2) of the contiguous surface area (2) are irradiated in immediate succession by means of the processing beam (4). [6] Method according to one of the preceding claims, in which the continuous surface area (2) is divided into a plurality of preferably rhomboid, in particular diamond-shaped, rectangular or square partial areas (T1, T2). [7] Method according to one of the preceding claims, in which the continuous surface area (2) is surrounded by an edge contour (9) of the three-dimensional component (20), wherein the edge contour (9) and / or an edge region (8) formed between the edge contour (9) and the continuous surface area (2) is irradiated with the processing beam (4, 4a) or with at least one further processing beam (4b, 4c). [8] Method for producing a continuous surface area (F1) of a three-dimensional component (20) by irradiating a powder layer (3) with at least one processing beam (4a-c), wherein in particular at least one further continuous surface area (F4) has at least one section (A4) which is arranged downstream of at least one section (A1) of the continuous surface area (F1) with respect to a flow vector (G) of a gas flow (13) guided over the powder layer (3) and which overlaps with the section (A1) of the continuous surface area (F1) transversely to the flow vector (G), comprising: Irradiating the contiguous surface area (F1) with at least one processing beam (4a-c) in at least one of a plurality of partial areas (T1, ..., Tn) into which the contiguous surface area (F1) is divided, until the powder layer (3) in the at least one partial area (T1, ..., Tn) is completely melted, wherein the irradiation of the partial areas (T1, ..., Tn) is repeated in immediate succession until all partial areas (T1, ..., Tn) of the contiguous surface area (F1) are completely melted, characterized by , that the contiguous surface area (F1) extends further downstream with respect to the flow vector (G) of the gas flow (13) than at least one further contiguous surface area (F2, F3, F4) and that the irradiation of the contiguous surface area (F1) begins before the irradiation of the further contiguous surface area (F2, F3, F4). [9] Method according to claim 8, wherein at least two processing beams (4a, 4b) irradiate at least two of the plurality of partial regions (T1, ..., Tn) of the contiguous surface region (F1) simultaneously. [10] Method according to one of claims 8 or 9, in which a first processing beam (4a) begins the irradiation of the contiguous surface area (F1) and a second processing beam (4b) either irradiates the contiguous surface area (F1) together with the first processing beam (4a) or begins the irradiation of a further contiguous surface area (F2, F3, F4). [11] Method according to claim 10, in which, in the event that the first and second processing beams (4a, 4b) hinder each other when jointly irradiating the contiguous surface area (F1), the first or the second processing beam (4a, 4b) immediately subsequently begins to irradiate a further contiguous surface area (F3, F4) or immediately subsequently irradiates a further contiguous surface area (F2) together with a third processing beam (4c). [12] Method according to one of claims 8 to 11, wherein the further contiguous surface area (F4) is not irradiated at the same time as the overlapping section (A1) of the contiguous surface area (F1), at least in the section (A4) which is arranged downstream of the section (A1) of the contiguous surface area (F1). [13] Irradiation device (1) for a processing machine (15) for producing three-dimensional components (20) by irradiating powder layers (3), comprising: at least one scanner device (5, 5a-c) for aligning at least one processing beam (4, 4a-c) onto a powder layer (3) in a processing plane (E), a control device (11) which is designed to control the scanner device (5, 5a-c), to move the processing beam (4) along a plurality of stripes (S1, S2, ...) over a contiguous surface area (2) in order to irradiate the contiguous surface area (2) in a respective stripe (S1, S2, ...) in a plurality of sub-areas (T1, T2) directly adjacent to one another along a respective stripe formation vector (H), and which is designed to control the scanner device (5, 5a-c), to move the processing beam (4) over a respective sub-area (T1, T2) in a scanning movement until the powder layer (3) in the respective sub-area (T1, T2, ...) is completely melted, characterized by , that the control device (11) is designed to control the scanner device (5), to scan a first partial area (T1) of a respective strip (S1, S2, ...) by means of the processing beam (4) in a first scanning direction (R1) and immediately thereafter to scan a second partial area (T2) of the strip (S1, S2, ...), which directly borders the first partial area (T1) along a common edge (10), by means of the processing beam (4) in a second scanning direction (R2) which is different from the first and in particular perpendicular to the first scanning direction, or that the control device (11) is designed to control the scanner device (5), to scan first partial areas (T1) of a first strip (S1, S3, S5, S7), which are directly adjacent to one another at certain points, by means of the processing beam (4) in a first scanning direction (R1), and immediately subsequently to scan second partial areas (T2), which are directly adjacent to one another at certain points, of a second strip (S2) immediately adjacent to the first, in a second scanning direction (R2) which is different from the first and in particular perpendicular to the first scanning direction (R2) by means of the processing beam (4). [14] Processing machine (15) for producing three-dimensional components (20) by irradiating powder layers (3), comprising: a processing chamber (16) with a processing plane (E) in which a powder layer (3) to be irradiated can be arranged, and preferably a supply device (14) for providing a gas stream (13) which flows over the processing plane (E) in a construction platform area (17) provided for the provision of a powder bed (19), characterized by an irradiation device (1) according to claim 13. [15] Processing machine according to the preamble of claim 14, further comprising: an irradiation device (1) having at least one scanner device (5a-c) for aligning at least one processing beam (4a-c) onto a powder layer (3) in a processing plane (E), and a control device (11) which is designed to control the at least one scanner device (5a-c), to irradiate a contiguous surface area (F1) with at least one processing beam (4a-c) in at least one of a plurality of partial areas (T1, ..., Tn) into which the contiguous surface area (F1) is divided, until the powder layer (3) in the at least one partial area (T1, ..., Tn) is completely melted, and wherein the control device (11) is designed to control the at least one scanner device (5a-c) to repeat the irradiation of the partial areas (T1, ..., Tn) in immediate succession until all partial areas (T1, ..., Tn) of the contiguous surface area (F1) are completely melted, wherein in particular at least one further contiguous surface area (F4) has at least one section (A4) which is arranged downstream of at least one section (A1) of the contiguous surface area (F1) with respect to a flow vector (G) of a gas flow (13) guided over the powder layer (3) and which overlaps transversely to the flow vector (G) with the section (A1) of the contiguous surface area (F1), characterized by , that the contiguous surface area (F1) extends further downstream with respect to the flow vector (G) of the gas flow (13) than at least one further contiguous surface area (F2) and in which the control device (11) is designed to control the at least one scanner device (5a-c) to begin the irradiation of the contiguous surface area (F1) before the irradiation of the further contiguous surface area (F2, F3, F4). [16] Processing machine according to claim 15, in which the control device (11) is designed to control the at least one scanner device (5a-c), to start the irradiation of the contiguous surface area (F1) with a first processing beam (4a) and to irradiate the contiguous surface area (F1) with a second processing beam (4b) either together with the first processing beam (4a) or to start the irradiation of a further contiguous surface area (F2, F3, F4). [17] Processing machine according to claim 16, in which, in the event that the first and second processing beams (4a, 4b) interfere with each other when jointly irradiating the contiguous surface area (F1), the control device (11) controls the at least one scanner device (5a-c) to immediately subsequently begin irradiating the further contiguous surface area (F3, F4) with the first or with the second processing beam (4a, 4b) or to immediately subsequently irradiate another contiguous surface area (F2) together with a third processing beam (4c). [18] Processing machine according to one of claims 15 to 17, in which the control device (11) is designed to control the at least one scanner device (5a-c) to irradiate the further contiguous surface area (F4), at least in the section (A4) which is arranged downstream of the section (A1) of the contiguous surface area (F1), not simultaneously with the overlapping section (A1) of the contiguous surface area (F1).

Images