Manufacturing equipment and method for the additive manufacturing of a component from a powder material, as well as a method for generating a specific intensity profile of an energy beam.

Abstract

Manufacturing equipment (1) for the additive manufacturing of components from a powder material, with - a beam generating device (3) which is configured to generate an energy beam (5), - a scanner device (7) which is set up to move the energy beam (5) within a working area (9) to a plurality of irradiation positions (11) in order to produce a component from the powder material arranged in the working area (9) by means of the energy beam (5), - a deflection device (13) configured to redirect the energy beam (5) from one irradiation position (11) of the plurality of irradiation positions (11) within a beam area (15) to a plurality of beam positions (17), and with - a control device (19) which is operatively connected to and configured with the deflection device (13) to control the deflection device (13) and to generate a specific intensity profile in the beam area (15) by displacing the energy beam (5) within the beam area (15) and by specifying at least one operating parameter of the deflection device (13), wherein the at least one operating parameter is selected from a group consisting of: a dwell time at a beam position (17), a beam position density distribution in the beam area (15), a frequency distribution of the beam positions (17), and an intensity control parameter for influencing the intensity of the energy beam (5) deflected to the respective beam positions (17).

Description

[0001] The invention relates to a manufacturing device and a method for additively manufacturing a component from a powder material, as well as a method for generating a specific intensity profile of an energy beam.

[0002] In the additive manufacturing of components from a powder material, an energy beam is typically shifted to predetermined irradiation positions within a work area—in particular along a predetermined irradiation path—in order to locally solidify powder material arranged in the work area. This is repeated, in particular, layer by layer in successive powder material layers arranged in the work area to ultimately obtain a three-dimensional component made of solidified powder material. For different manufacturing tasks, in particular for different components to be produced, but also for different regions within a component to be manufactured, and even for different regions within a single powder material layer in the work area, it may be advantageous to expose the powder material to different intensity profiles of the energy beam.In particular, a suitable selection of the intensity profile can contribute to increasing productivity. Generating suitable, customized intensity profiles using conventional beam shaping, especially using refractive or interferometric optical elements in an optical energy beam, is often complex and not flexible. In particular, it is difficult to switch between different intensity profiles during a single manufacturing process, especially within a single layer of powder material. Furthermore, conventional beam shaping methods only allow the representation of a limited selection of intensity profiles and are therefore also limited in their applicability.

[0003] EP 3 628 488 A1 discloses a manufacturing device for the additive manufacturing of components from a powder material, comprising a beam generating device configured to generate an energy beam, a scanner device configured to shift the energy beam within a work area to a plurality of irradiation positions in order to produce a component from the powder material arranged in the work area by means of the energy beam, a deflection device configured to shift the energy beam at an irradiation position of the plurality of irradiation positions within a beam area to a plurality of beam positions, and a control device operatively connected to the deflection device and configured to control the deflection device.

[0004] EP 2 514 553 A2 discloses a change in the beam profile of an energy beam by means of a deformable reflecting means and thus a direct and instantaneous influence on the beam profile.

[0005] From Heberle, J. et al.: Electro-optic and acousto-optic laser beam scanners. In: Proceedings of SPIE, Vol. 9736, 2016; doi: 10.1117 / 12.2212208, pp. 97360L-1 - 97360L-10, it emerges that the profile of a laser pulse deflected by an acousto-optic deflector can be instantaneously modified by applying a specific frequency response to the acousto-optic deflector, resulting in a kind of cylindrical lens effect.

[0006] The invention is based on the object of creating a manufacturing device and a method for the additive manufacturing of components from a powder material and a method for generating a specific intensity profile of an energy beam, wherein the aforementioned disadvantages are at least reduced, preferably avoided.

[0007] The object is achieved by providing the present technical teaching, in particular the teaching of the independent claims as well as the embodiments disclosed in the dependent claims and the description.

[0008] The object is achieved in particular by providing a manufacturing device for the additive manufacturing of components from a powder material, which manufacturing device has a beam generation device configured to generate an energy beam. The manufacturing device also has a scanner device configured to shift the energy beam within a work area to a plurality of irradiation positions in order to produce a component from the powder material arranged in the work area by means of the energy beam. Furthermore, the manufacturing device has a deflection device configured to shift the energy beam at one of the plurality of irradiation positions within a beam area to a plurality of beam positions.Furthermore, the production device comprises a control device operatively connected to the deflection device and configured to control the deflection device and to generate a specific intensity profile in the beam region by shifting the energy beam within the beam region and by specifying at least one operating parameter of the deflection device. The at least one operating parameter is selected from a group consisting of: a dwell time at a beam position, a beam position density distribution in the beam region, a frequency distribution of the beam positions, and an intensity influencing parameter for influencing the intensity of the energy beam deflected to the respective beam positions.

[0009] In this way, a specific intensity profile can be specified and generated easily and quickly, without the need for special equipment, especially equipment specific to the intensity profile. In particular, it is possible to switch between different intensity profiles easily and quickly. The production facility is thus very flexible, capable of generating a suitable intensity profile adapted to the respective component to be manufactured and / or the respective areas of a component to be manufactured. It thus exhibits a particularly high level of productivity. The quality of the components manufactured with the production facility can also be increased by selecting particularly suitable intensity profiles.Since there is no need for optical elements specifically adapted to the intensity profiles, particularly refractive or static interferometric optical elements, the production facility is cost-effective despite its high degree of flexibility, particularly considering that it eliminates the need for different devices to generate different intensity profiles. The production facility proposed here also allows, through appropriate control of the scanner device on the one hand and the deflection device on the other, a switch between the most efficient, and particularly fast, component production and a particularly high-quality production, in particular with locally varying adjustment of the material properties for the resulting component, for example, a higher hardness in the area of ​​the component surface than in the interior of the component.

[0010] Additive or generative manufacturing of a component is understood to mean, in particular, a layered buildup of a component from powder material, in particular a powder-bed-based process for producing a component in a powder bed, in particular a manufacturing process selected from a group consisting of selective laser sintering, laser metal fusion (LMF), direct metal laser melting (DMLM), laser net shaping manufacturing (LNSM), and laser engineered net shaping (LENS). The manufacturing facility is therefore particularly configured to carry out at least one of the aforementioned additive or generative manufacturing processes.

[0011] An energy beam is generally understood to be directed radiation capable of transporting energy. This can generally be particle radiation or wave radiation. In particular, the energy beam propagates through physical space along a propagation direction, transporting energy along its propagation direction. In particular, the energy beam makes it possible to deposit energy locally in the work area.

[0012] In a preferred embodiment, the energy beam is an optical working beam. An optical working beam is understood in particular to be directed electromagnetic radiation, continuous or pulsed, which, with regard to its wavelength or a wavelength range, is suitable for the additive or generative manufacturing of a component from powder material, in particular for sintering or melting the powder material. In particular, an optical working beam is understood to be a laser beam, which can be generated continuously or in pulsed form. The optical working beam preferably has a wavelength or a wavelength range in the visible electromagnetic spectrum or in the infrared electromagnetic spectrum, or in the overlap range between the infrared range and the visible range of the electromagnetic spectrum.

[0013] A work area is understood to be an area, in particular a plane or surface, in which the powder material is arranged and which is locally exposed to the energy beam in order to locally solidify the powder material. In particular, the powder material is arranged sequentially in layers in the work area and locally exposed to the energy beam in order to produce a component layer by layer.

[0014] An irradiation position is understood, in particular, to be a location within the work area at which energy is locally deposited into the work area, in particular into the powder material arranged there, by means of the energy beam. The scanner device is preferably configured to displace the energy beam within the work area along an irradiation path, wherein the irradiation path consists of a temporal sequence of irradiation positions swept successively by the energy beam. The individual irradiation positions can be spaced apart from one another, but can also overlap one another. In particular, the irradiation path can be a path continuously scanned by the energy beam.

[0015] A beam area is understood here, in particular, to be an area at an irradiation position within which the specific intensity profile is generated. The beam area, in particular, has a surface area that is larger than the cross-section of the energy beam projected onto the working area.

[0016] The deflection device is thus particularly configured to shift the energy beam at a fixed irradiation position, in particular at each irradiation position, within the beam area and thus to expose a specific area—the beam area—within the working area at the fixed irradiation position to the energy beam, which area is larger than the cross-section of the energy beam projected onto the working area. In contrast, the scanner device is configured to shift the energy beam between the individual irradiation positions and thus, in turn, enable the deflection device to sweep a new beam area at a different location with the energy beam. The deflection device thus serves to locally deflect the energy beam at an irradiation position, while the scanner device serves to globally shift the energy beam within the working area.

[0017] The scanner device and the deflection device thus differ in particular with regard to a length scale of the possible displacement, wherein the scanner device is preferably configured to sweep the entire working area with the energy beam, wherein the deflection device is configured to deflect the energy beam locally at an irradiation position predetermined by the scanner device within the beam area, wherein the respective beam area is much smaller than the working area.In particular, the beam region preferably has a length scale in the range of a few (i.e. less than ten) millimeters to a few centimeters, and preferably a planar extent in the range of a few square millimeters to a few square centimeters, while the working region has a length scale in the range of a few decimeters to a few meters, and preferably a planar extent in the range of a few square decimeters to a few square meters.

[0018] The scanner device, on the one hand, and the deflection device, on the other hand, preferably also differ with regard to the time scale on which the energy beam is deflected: In particular, the deflection of the energy beam by the deflection device within the beam region preferably occurs on a shorter, in particular much shorter, time scale than the deflection within the working area by the scanner device, i.e., as the change from one irradiation position to the next irradiation position. In this way, a specific intensity profile can advantageously be generated quasi-statically by means of the deflection device at each irradiation position, which is predetermined by a current setting of the scanner device, by appropriately shifting the energy beam within the beam region.Preferably, the time scale on which the energy beam can be deflected by the deflection device is smaller by a factor of 10 to 1000, preferably 20 to 200, preferably 40 to 100, or more, than the time scale on which a deflection of the energy beam occurs by the scanner device.

[0019] The generated intensity profile is also quasi-static with respect to the melting process in the powder material, with the timescale for the deflection of the energy beam by the deflection device being significantly shorter than the characteristic interaction time of the energy beam with the powder material. The dynamically generated intensity profile thus interacts with the powder material, averaged over time, like a statically generated intensity profile.

[0020] An intensity profile is understood here, in particular, to be a surface power density distribution on a surface exposed to, in particular swept over, the energy beam. The intensity profile thus includes, in particular, as parameters that can preferably be changed separately, the local surface power density, in particular the intensity of the energy beam, and the spatial distribution of the surface power density. The term "power" refers in particular to a power averaged over the timescale of the generation of a quasi-static intensity profile within a beam area at one of the irradiation positions.

[0021] The at least one operating parameter of the deflection device is in particular a displacement parameter or an intensity influencing parameter.

[0022] A displacement parameter is understood here, in particular, to be a parameter that at least partly determines the displacement of the energy beam within the beam region. In particular, the displacement parameter determines, for example, how long the energy beam remains at a specific beam position, how different beam positions are arranged relative to one another within the beam region, and how / or how often specific beam positions are addressed with the energy beam. In particular, the following operating parameters are thus displacement parameters: the residence time at a beam position, the beam position density distribution in the beam region, and the frequency distribution of the beam positions.

[0023] A dwell time at a beam position is, in particular, the time interval for which the energy beam remains at a specific beam position within the beam region before being shifted to the next beam position. The dwell time thus directly determines the energy deposited at the beam position. The dwell time can preferably also be determined by a displacement velocity of the energy beam within the beam region.

[0024] A beam position density distribution in the beam region is understood to mean, in particular, how an areal density of the beam positions in the beam region is configured, in particular how high the areal density of the beam positions is, and whether the areal density of the beam positions in the beam region is homogeneous, i.e., in particular, constant, or varying, as well as whether and, if so, how the areal density of the beam positions in the beam region varies. The higher the areal density of the beam positions, the higher the local intensity in the beam region, while the lower the areal density of the beam positions, the lower the local intensity. The beam position density distribution is preferably determined, in particular, by the distances between adjacent beam positions within the beam region.

[0025] A frequency distribution of the beam positions is understood in particular as a measure of how frequently the individual beam positions within the beam region are addressed or exposed to the energy beam. In particular, a configuration is possible in which the energy beam reaches at least some of the beam positions multiple times - optionally with a constant dwell time at the various beam positions. Assuming a homogeneous, i.e. constant, beam position density distribution in the beam region, the intensity profile is flat or has a constant intensity in the beam region if all beam positions are addressed with the energy beam equally frequently. An intensity profile deviating from constancy or homogeneity can be generated by addressing different beam positions with the energy beam or exposing them to the energy beam with different frequencies.More energy is then deposited at the more frequently addressed beam positions than at the less frequently addressed beam positions.

[0026] The energy or fluence of the energy beam is preferably constant over time. According to a preferred embodiment, the intensity distribution, i.e., the intensity profile, within the beam region thus depends only on the corresponding specification of the at least one displacement parameter.

[0027] It is obvious that the intensity profile is influenced by the appropriate choice of the residence time at a beam position, the beam position density distribution in the beam region, and / or the frequency distribution of the beam positions in the beam region.

[0028] An intensity profile can therefore be generated very easily and flexibly by appropriately specifying at least one displacement parameter in the beam area.

[0029] Alternatively or additionally, the at least one operating parameter is an intensity-influencing parameter. This is suitable for influencing, in particular changing, the intensity of the energy beam deflected to the respective beam positions, in particular the energy or fluence of the energy beam.

[0030] According to a preferred embodiment, it is possible in this way - in particular by suitable specification of a displacement parameter and an intensity influencing parameter - to smooth in particular edge regions of the generated intensity profile by, preferably in addition to the suitable specification of the displacement parameter, suitably changing the intensity of the energy beam there, in particular by attenuating it - stepwise or continuously - towards the edge.

[0031] The intensity of the energy beam can preferably be changed additionally or alternatively by changing the intensity of the energy beam provided by the beam generating device, in particular by suitable control of the beam generating device.

[0032] The control device is preferably selected from a group consisting of a computer, in particular a personal computer (PC), a plug-in card or control card, and an FPGA board. In a preferred embodiment, the control device is an RTC6 control card from SCANLAB GmbH, in particular in the version currently available on the date determining the priority of the present patent.

[0033] The control device is preferably configured to synchronize the scanner device with the deflection device using a digital RF synthesizer, wherein the RF synthesizer is controlled via a programmable FPGA board. In addition, a division into the comparatively slow movement of the scanner device and the fast movement of the deflection device preferably occurs using a frequency divider. Preferably, position values ​​and default values ​​for a beam profile, i.e., the intensity profile and a shape of the beam area, are calculated, which are then converted in the FPGA board into temporally synchronous frequency defaults for the RF synthesizer. Prior to this, the beam profiles must be spatially assigned to irradiation positions in the respective powder material layer, which is preferably performed in a build processor. This build processor writes the corresponding data to a file, which is then preferably used by the control device.Alternatively or additionally, it is preferably possible to select from predefined beam profiles.

[0034] According to a further development of the invention, the control device is configured to change the intensity profile by varying the at least one operating parameter, in particular the at least one displacement parameter and / or the at least one intensity-influencing parameter. Thus, the intensity profile can advantageously be adjusted in a simple and rapid manner, particularly as needed.

[0035] According to a further development of the invention, the control device is configured to generate the intensity profile as a Gaussian intensity profile. In particular, this can also be a Gaussian profile elongated along a direction within the working area, wherein the axis of longest extension of the Gaussian profile, in a preferred embodiment, can extend perpendicular to an irradiation path, i.e., a particularly local displacement direction within the working area, of the energy beam, or along the irradiation path of the energy beam. Of course, it is also possible for the axis of longest extension of the Gaussian profile to extend obliquely to the irradiation path.

[0036] Alternatively, it is possible that the intensity profile is generated as a non-Gaussian intensity profile.

[0037] Alternatively or additionally, the control device is configured to generate the intensity profile as a constant intensity profile, in particular in the manner of a flat-top beam.

[0038] Alternatively or additionally, the control device is configured to generate the intensity profile as an asymmetric or distorted intensity profile.

[0039] The control device is thus particularly capable of generating a plurality of different intensity profiles, in particular any desired intensity profiles.

[0040] According to a further development of the invention, it is provided that the control device is configured to additionally specify a shape of the beam region by controlling the deflection device.

[0041] The shape of the beam area refers in particular to the geometry of an outer boundary of the beam area or, equivalently, to the shape of the area swept quasi-statically by the energy beam within the beam area. This corresponds to a quasi-static cross-sectional profile of the energy radiation with which the working area is exposed at the respective irradiation position.

[0042] Preferably, the control device is configured to generate the shape of the beam region as a circular shape, as a ring shape, in particular a torus or donut shape, as a polygon, as a rectangle, as an elongated shape, in particular with rounded ends, and / or as an irregular shape.

[0043] The control device is preferably configured, in particular, to specify a beam profile by controlling the deflection device, wherein the beam profile comprises, on the one hand, the shape of the beam region and, on the other hand, the intensity profile within the beam region. The manufacturing device is thus particularly flexible in adapting the exposure of the energy beam to the working area to the conditions for manufacturing a component, in particular to changing, particularly locally varying, conditions.

[0044] According to a further development of the invention, the control device is configured to change the intensity profile during the production of a component, in particular within the working area, by varying the at least one operating parameter, in particular the at least one displacement parameter and / or the at least one intensity influencing parameter. In this way, the intensity profile can be flexibly adapted to different conditions or requirements during the production of a component. Particularly preferably, the control device is configured to change the intensity profile within a single powder material layer during the layer-by-layer construction of a component by varying the at least one operating parameter. This enables particularly flexible adaptation of the intensity profile.For example, a different intensity profile can be selected for an outer envelope area of ​​the resulting component, i.e. in particular for its surface, than for an inner area within the outer envelope area of ​​the component.

[0045] Alternatively or additionally, the control device is preferably configured to change the shape of the beam region during the production of a component, in particular within the working area, by varying the at least one operating parameter, in particular the at least one displacement parameter and / or the at least one intensity influencing parameter. In this way, the shape of the beam region can be flexibly adapted to different conditions or requirements during the production of a component. Particularly preferably, the control device is configured to change the shape of the beam region within a same powder material layer during the layer-by-layer construction of a component by varying the at least one operating parameter. This enables a particularly flexible adaptation of the shape of the beam region.For example, a different shape of the beam area can be selected for an outer envelope area of ​​the resulting component than for an inner area within the outer envelope area of ​​the component.

[0046] The intensity profile and / or the shape of the beam area can be selected alternatively or additionally, in particular depending on whether a contour, a core, an overhang area, a cover layer area, or a volume area of ​​the resulting component is being processed.

[0047] A contour is the outline or outer boundary of an area within a powder material layer that is to be solidified or has been solidified. A core is an area within the contour in the powder material layer.

[0048] An overhang area is an area within a powder material layer below which, i.e., in the underlying powder material layers, there is unconsolidated powder material. Such an overhang is also referred to as a "down skin." This term also refers to the lowest powder material layer containing consolidated powder material, i.e., a bottom surface of the component.

[0049] A cover layer area is an area within a powder material layer above which, i.e., in the overlying powder material layers, there is unconsolidated powder material. Such a cover layer area is also referred to as the "up skin." This term also refers to the uppermost powder material layer that still contains solidified powder material, i.e., a roof surface or uppermost surface of the component.

[0050] A bulk area is an area within a powder material layer that is surrounded on all sides by solidified powder material in the finished component, particularly within the powder material layer, but also above and below the powder material layer being machined. Such an area is also referred to as "in skin."

[0051] Different intensity profiles and / or shapes of the beam range can also be used, on the one hand, for delicate structures of a component, which are, for example, on the order of magnitude of the beam range, and on the other hand, for coarser, larger, particularly flat structures. If necessary, delicate structures, in particular closed structural sections, can also be created solely by controlling the deflection device and generating a local beam profile at a fixed irradiation position, without controlling the scanner device, in particular by generating a beam profile in the shape of the structural section to be formed by appropriately controlling the deflection device.

[0052] Specifying the intensity profile and / or the shape of the beam area depending on the current irradiation position also makes it possible to influence the resulting component structure via the intensity distribution. For example, the grain structure of the resulting component changes when irradiated with changing temperature gradients and solidification conditions. This allows local strength values ​​or surface hardness to be influenced and, in particular, locally varied.

[0053] In particular, it is possible to harden the outer surface of the component by creating a higher hardness of the solidified powder material in up-skin or down-skin areas in several powder material layers arranged directly below or above it. Accordingly, contour lines can also be hardened to a greater extent in individual powder material layers.

[0054] According to a further development of the invention, the deflection device is arranged in front of the scanner device in the propagation direction of the energy beam, i.e., the direction of spatial propagation of the energy radiation. This represents a particularly suitable configuration for flexible generation of the intensity profile and / or the shape of the beam region. The term "in front of" refers to the fact that the deflection device is reached first by the energy beam during propagation of the energy beam along the propagation direction, with the scanner device being reached subsequently by the energy beam.

[0055] According to a further development of the invention, it is provided that the deflection device has at least one acousto-optical deflector.

[0056] An acousto-optical deflector is understood in particular to be an element comprising a solid body transparent to the energy beam, which can be exposed to sound waves, in particular ultrasonic waves. The energy beam is deflected as it passes through the transparent solid body depending on the frequency of the sound waves exposed to the transparent solid body. In this case, the sound waves, in particular, generate an optical grating in the transparent solid body. Such acousto-optical deflectors are advantageously capable of deflecting the energy beam very quickly by an angular range predetermined by the frequency of the sound waves generated in the transparent solid body. In particular, switching speeds of up to 1 MHz can be achieved.In particular, the switching times for such an acousto-optic deflector are significantly faster than typical switching times for conventional scanner optics, especially galvanometer scanners, which are generally used to shift an energy beam within a work area of ​​a manufacturing facility of the type discussed here. Therefore, such an acousto-optic deflector can be used particularly suitably for generating a quasi-static intensity profile in the beam area.

[0057] Modern acousto-optical deflectors deflect the energy beam into a predetermined angular range of the first order of diffraction with an efficiency of at least 90%, making them ideally suited as deflection devices for the manufacturing facility proposed here. Key factors for this high efficiency are the material used, which is transparent to the energy beam, and a suitably high intensity of the coupled ultrasonic waves.

[0058] According to a preferred embodiment, the intensity-influencing parameter is specified by operating or using the at least one acousto-optical deflector as an acousto-optical modulator. Alternatively or additionally, it is preferably provided that an intensity of the sound waves coupled into the transparent solid of the at least one acousto-optical deflector is specified as the intensity-influencing parameter. In this way, the intensity of the energy beam deflected to the respective beam position can be very easily influenced. In particular, the deflected intensity of the energy beam preferably depends—preferably linearly—on the intensity of the sound waves radiated into the transparent solid.

[0059] In a preferred embodiment, the deflection device comprises two acousto-optical deflectors that are not oriented parallel to one another, but are preferably oriented perpendicular to one another. This advantageously allows deflection of the energy beam in two directions that are not parallel to one another, in particular perpendicular to one another. The acousto-optical deflectors, which are not oriented parallel to one another, but are preferably oriented perpendicular to one another, are preferably arranged one behind the other in the propagation direction of the energy beam.

[0060] By “behind” is meant here in particular that an element arranged behind another element is reached by the energy beam when the energy beam propagates along the propagation direction after the other element, analogous to the definition of “in front of” given above.

[0061] According to a further development of the invention, the production device comprises a separation mirror downstream of the deflection device and upstream of the scanner device in the propagation direction of the energy beam, which separation mirror is configured to separate a zero-order partial beam of the energy beam from a first-order partial beam. In particular, if the deflection device comprises an acousto-optical deflector, its design, analogous to an optical grating, generates an undiffracted zero-order partial beam and a diffracted or deflected first-order partial beam. Only the first-order partial beam is to be used to irradiate the work area. Using the separation mirror, it is advantageously possible to separate the partial beams of different orders from one another while allowing only the first-order partial beam to pass through to the work area, in particular to the scanner device.The zero-order partial beam is preferably deflected into a beam trap by the separation mirror.

[0062] This representation is correct for the use of exactly one acousto-optical deflector. If, in a preferred embodiment, two acousto-optical deflectors are used that are not oriented parallel to one another, but are preferably oriented perpendicular to one another, the corresponding diffraction orders must also be considered cumulatively: The useful beam should ultimately be the partial beam that initially strikes the second acousto-optical deflector as a first-order partial beam, and is then diffracted again as a first-order partial beam by the second acousto-optical deflector. In this case, the useful beam as a "first-order partial beam" is essentially a first-order partial beam. To keep the representation simple, however, we will always refer to the first order in the following.

[0063] In particular, the separation mirror preferably has a through-hole in a surface reflecting the energy beam, through which the first-order partial beam passes the separation mirror toward the working area, in particular toward the scanner device. The zero-order partial beam—and preferably also unwanted partial beams of a higher order than the first order—impinge on the reflecting surface and are deflected into the beam trap by the separation mirror.

[0064] Preferably, the separation mirror is located near an intermediate focus of a telescope. This allows for a particularly clean separation of the partial beams of different orders.

[0065] Preferably, the separation mirror is not arranged exactly in the intermediate focus of the telescope, in particular to avoid damage to the separation mirror due to an excessively high power density of the energy beam.

[0066] Preferably, the separation mirror is offset along the propagation direction at a distance of one-fifth of the focal length of the telescope from the intermediate focus, preferably in front of the intermediate focus in the propagation direction. This ensures, on the one hand, a clean separation of the various sub-beams of different orders and, on the other hand, a sufficiently low power density of the energy beam on the separation mirror to prevent damage by the energy beam.

[0067] The telescope is preferably a 1:1 telescope, meaning it has neither a beam-reducing nor a beam-enlarging property. In particular, the telescope fulfills two tasks: in addition to separating the various partial beams of different orders, it preferably also images a beam pivot point onto a point in the propagation direction behind the telescope. The imaged beam pivot point preferably lies either on a pivot point of the downstream scanner device or on a point of smallest aperture.

[0068] Strictly speaking, this consideration also only applies to the use of a single acousto-optical deflector. If two acousto-optical deflectors are used that are not oriented parallel to each other, but preferably oriented perpendicular to each other, two beam pivot points result, namely one in each acousto-optical deflector. However, if the two acousto-optical deflectors are arranged as close as possible to one another in the propagation direction, a single, imaginary common beam pivot point can be assumed to be a good approximation, which is then arranged between the acousto-optical deflectors.

[0069] According to a further development of the invention, the scanner device comprises at least one scanner, in particular a galvanometer scanner, piezo scanner, polygon scanner, MEMS scanner, and / or a working head or processing head that can be displaced relative to the work area. The scanner devices proposed here are particularly suitable for displacing the energy beam within the work area between a plurality of irradiation positions.

[0070] A working head or processing head that can be displaced relative to the work area is understood here in particular to mean an integrated component of the manufacturing facility that has at least one radiation outlet for at least one energy beam. The integrated component, i.e., the working head, can be displaced as a whole relative to the work area along at least one displacement direction, preferably along two mutually perpendicular displacement directions. Such a working head can, in particular, be designed as a gantry or be guided by a robot. In particular, the working head can be designed as a robot hand of a robot.

[0071] According to a further development of the invention, the beam generating device is designed as a laser. The energy beam is thus advantageously generated as an intense beam of coherent electromagnetic radiation, in particular coherent light.

[0072] According to a further development of the invention, the manufacturing facility is configured for selective laser sintering. Alternatively or additionally, the manufacturing facility is configured for selective laser melting. These configurations of the manufacturing facility have proven particularly advantageous.

[0073] The object is also achieved by providing a method for generating a specific intensity profile of an energy beam in a beam region on a work area of ​​a manufacturing facility for the additive manufacturing of components from a powder material. The specific intensity profile is generated by displacing the energy beam within the beam region and by specifying at least one operating parameter for the energy beam, wherein the at least one operating parameter is selected from a group consisting of: a dwell time at a beam position in the beam region, a beam position density distribution in the beam region, a frequency distribution of the beam positions in the beam region, and an intensity influencing parameter for influencing the intensity of the energy beam deflected to the respective beam positions.In connection with the process, the advantages that have already been explained in connection with the production facility arise in particular.

[0074] According to a further development of the invention, a specific shape of the beam region is additionally generated by specifying at least one operating parameter. This allows both the intensity profile and the specific shape of the beam region to be generated in a very flexible manner.

[0075] According to a further development of the invention, the shape of the beam region and / or the intensity profile is / are changed by varying at least one operating parameter. Thus, the beam region can be adapted very flexibly with regard to its shape and / or intensity profile, in particular to existing requirements and / or to increase productivity.

[0076] According to a further development of the invention, the intensity profile is additionally generated, preferably modified, by changing the intensity of the energy beam provided by the beam generating device, in particular by controlling the beam generating device. This advantageously provides a further degree of freedom for influencing the intensity of the energy beam. Such influencing is particularly simple if a laser is used as the beam generating device, in which the intensity of the generated energy beam can be easily and quickly changed.

[0077] The object is finally also achieved by creating a method for the additive manufacturing of a component from a powder material. Within the scope of the method, a manufacturing device according to the invention or a manufacturing device according to one of the previously described embodiments is used. Alternatively or additionally, within the scope of the method, a method according to the invention for generating a specific intensity profile of an energy beam or such a method according to one of the previously described embodiments is used. In connection with the method for additive manufacturing, the advantages that have already been described in connection with the manufacturing device and / or the method for generating a specific intensity profile arise in particular.

[0078] In a preferred embodiment, the shape of the beam region and / or the intensity profile is / are changed during the production of the component, in particular within the working region, in particular within a same powder material layer during the layer-by-layer construction of a component, by varying the at least one operating parameter.

[0079] The invention is explained in more detail below with reference to the drawings, which show: Fig. 1 shows an embodiment of a manufacturing device for the additive manufacturing of components from a powder material; Fig. 2 a schematic representation of different intensity profiles, and Fig. 3 a schematic representation of a plurality of different shapes of a beam area.

[0080] Fig. 1 shows a schematic representation of an embodiment of a manufacturing facility 1 configured for the additive manufacturing of components from a powder material. The manufacturing facility 1 comprises a beam generation device 3 configured to generate an energy beam 5. Furthermore, the manufacturing facility 1 comprises a scanner device 7 configured to displace the energy beam 5 within a work area 9 to a plurality of irradiation positions 11 in order to use the energy beam 5 to produce a component from the powder material arranged in the work area 9.

[0081] The manufacturing device 1 has a deflection device 13 which is configured to shift the energy beam 5 at an irradiation position 11 of the plurality of irradiation positions 11 within a beam region 15 to a plurality of beam positions 17.

[0082] The production device 1 has a control device 19, which is operatively connected to the deflection device 13 and configured to control the deflection device 13 and to generate a specific intensity profile in the beam region 15 by specifying at least one operating parameter of the deflection device 13. The at least one operating parameter is selected from a group consisting of: a dwell time at a beam position 17, a beam position density distribution in the beam region 15, a frequency distribution of the beam positions 17, and an intensity influencing parameter for influencing the intensity of the energy beam 5 deflected to the beam positions 17.

[0083] In this way, it is possible in a simple and extremely flexible manner to represent a specific intensity profile, in particular as a quasi-static intensity profile, whereby in particular complex intensity profiles can be easily represented, which otherwise could only be represented with difficulty or not at all with conventional steel-forming elements, in particular as static intensity profiles.

[0084] The at least one operating parameter of the deflection device is in particular a displacement parameter or an intensity influencing parameter.

[0085] The control device 19 is in particular configured to change the intensity profile by varying the at least one operating parameter.

[0086] The control device 19 is in particular configured to generate the intensity profile as a Gaussian, non-Gaussian, constant, asymmetric or distorted intensity profile.

[0087] The control device 19 is in particular configured to additionally predetermine a shape of the beam region 15, wherein the control device 19 is in particular configured to predetermine a beam profile, comprising the shape of the beam region 15 and the intensity profile in the beam region 15, by controlling the deflection device 13.

[0088] The control device 19 is particularly configured to change the intensity profile and / or the shape of the beam region 15 during the production of a component, in particular within the working area 9, by varying the at least one operating parameter. In particular, this can be carried out within a single powder material layer, for example in order to apply different intensity profiles and / or shapes of the beam region to different regions of the powder material layer, in particular an outer region on the one hand and an inner region on the other. The intensity profile and / or the shape of the beam region can be selected alternatively or additionally, in particular depending on whether a contour, a core, an overhang region, a cover layer region, or a volume region of the resulting component is being machined.

[0089] The deflection device 13 is arranged in front of the scanner device 7, in particular in the propagation direction of the energy beam 5.

[0090] The deflection device 13 has, in particular, at least one acousto-optical deflector 21, here in particular two acousto-optical deflectors 21 that are not oriented parallel to one another, but are preferably oriented perpendicular to one another, namely a first acousto-optical deflector 21.1 and a second acousto-optical deflector 21.2. The acousto-optical deflectors 21, which are oriented perpendicular to one another in this case, allow a deflection of the energy beam 5 in two mutually perpendicular directions and thus, in particular, a planar scanning of the beam region 15. The acousto-optical deflectors 21 are preferably additionally controlled as acousto-optical modulators, and / or the intensity of sound waves coupled into the transparent solid of at least one acousto-optical deflector 21 of the two acousto-optical deflectors 21 is varied in order to vary the intensity of the energy beam 5.

[0091] The production device 1 also has a separation mirror 23 located behind the deflection device 13 and in front of the scanner device 7 in the propagation direction of the energy beam 5. The separation mirror 23 is configured to separate a zero-order partial beam from a first-order partial beam of the energy beam 5. For this purpose, the separation mirror 23 has, in particular, a through-bore 25 provided in a surface 27 of the separation mirror 23 that reflects the energy beam 5 and completely penetrates the separation mirror 23. The first-order partial beam, which is to be forwarded to the scanner device 7 in the desired manner, is guided through the through-bore 25 and thus ultimately reaches the scanner device 7. The undesired zero-order partial beam, as well as possibly also undesired higher-order partial beams, impinge on the reflective surface 27 and are deflected to a beam trap 29.

[0092] The separation mirror 23 is arranged in particular in the vicinity of an intermediate focus 31 of a telescope 33, in particular not exactly in a plane of the intermediate focus 31, particularly preferably offset at a distance of one fifth of the focal length of the telescope 33 along the propagation direction, in particular in front of the intermediate focus 31. This advantageously prevents the reflective surface 27 from being exposed to an excessively high power density of the energy beam 5.

[0093] The telescope 33 preferably has a first lens 35 and a second lens 37. It is preferably designed as a 1:1 telescope. The telescope 33 preferably has a focal length of 500 mm.

[0094] The functionality of the telescope 33 is preferably twofold: Firstly, the telescope 33 enables, particularly with the arrangement of the separation mirror 23 chosen here, a particularly advantageous and clean separation of the different orders of the energy beam 5 deflected by the deflection device 13; secondly, the telescope 33 preferably advantageously images an imaginary, common beam pivot point 39 of the deflection device 13 onto a pivot point 41 of the scanner device 7.

[0095] Alternatively, the telescope 33 preferably images the beam pivot point 39 onto a point of smallest aperture.

[0096] In order to enable a compact arrangement of the production device 1, the energy beam 5 is preferably deflected several times by deflecting mirrors 43.

[0097] The scanner device 7 preferably has at least one scanner, in particular a galvanometer scanner, piezo scanner, polygon scanner, MEMS scanner and / or working head.

[0098] The beam generating device 3 is preferably designed as a laser.

[0099] The manufacturing device 1 is preferably configured for selective laser sintering and / or selective laser melting.

[0100] Within the scope of a method for generating a specific intensity profile of the energy beam 5 in the beam region 15 on the work area 9, the specific intensity profile is preferably generated by specifying at least one operating parameter for the energy beam, which is selected from the group consisting of the residence time at a beam position 17 in the beam region 15, the beam position density distribution in the beam region 15, the frequency distribution of the beam positions 17 in the beam region 15, and an intensity influencing parameter for influencing the intensity of the energy beam 5 deflected to the beam positions 17.

[0101] In addition, a specific shape of the beam region 15 is preferably generated by specifying the at least one operating parameter.

[0102] The shape of the beam region 15 and / or the intensity profile is / are preferably changed by varying the at least one operating parameter.

[0103] Within the scope of a method for additively manufacturing a component from a powder material, the manufacturing device 1 proposed here is preferably used, and / or a method of the type described above is used. Preferably, the shape of the beam region 15 and / or the intensity profile is / are changed during the production of the component, in particular within the working area 9, by varying at least one operating parameter.

[0104] The intensity profile is preferably additionally generated, preferably changed, by changing the intensity of the energy beam 5 provided by the beam generating device 3, in particular by controlling the beam generating device 3.

[0105] Fig. 2 shows a schematic representation of a plurality of intensity profiles in the beam region 15, as can be generated, for example, with the deflection device 13.

[0106] In a), a first Gaussian intensity profile 45 is shown.

[0107] At b), a second, non-Gaussian intensity profile 47 is shown, in which in particular the maximum of the intensity profile is shifted within the beam region 15, preferably towards a front of a displacement direction of the beam region 15 on the working region 9.

[0108] At c), a third, asymmetric or distorted intensity profile 49 is shown, in which not only in particular the maximum is arranged off-center within the beam region 15, but in addition the intensity profile on the right side also has a significantly higher intensity than on the left side in the beam region 15.

[0109] Fig.3 shows a schematic representation of a plurality of shapes of the beam region 15.

[0110] In a), a first, circular shape 51 for the beam area 15 is shown.

[0111] In b) a second, polygonal, here in particular hexagonal shape 53 is shown for the beam area 15.

[0112] At c) a third, rectangular shape 55 for the beam area 15 is shown.

[0113] At d) a fourth, elongated shape 57 for the beam area 15 with rounded ends is shown.

[0114] Finally, at e) a fifth, annular, torus-shaped or donut-shaped shape 59 for the beam area 15 is shown.

Claims

[1] Manufacturing device (1) for the additive manufacturing of components from a powder material, with - a beam generating device (3) which is arranged to generate an energy beam (5), - a scanner device (7) which is designed to displace the energy beam (5) within a working area (9) to a plurality of irradiation positions (11) in order to produce a component from the powder material arranged in the working area (9) by means of the energy beam (5), - a deflection device (13) which is designed to shift the energy beam (5) at an irradiation position (11) of the plurality of irradiation positions (11) within a beam area (15) to a plurality of beam positions (17), and with - a control device (19) which is operatively connected to the deflection device (13) and is designed to control the deflection device (13) and to generate a specific intensity profile in the beam region (15) by displacing the energy beam (5) within the beam region (15) and by specifying at least one operating parameter of the deflection device (13), wherein the at least one operating parameter is selected from a group consisting of: a residence time at a beam position (17), a beam position density distribution in the beam region (15), a frequency distribution of the beam positions (17), and an intensity influencing parameter for influencing the intensity of the energy beam (5) deflected to the beam positions (17). [2] Manufacturing device (1) according to claim 1, wherein the control device (19) is arranged to change the intensity profile by varying the at least one operating parameter. [3] Manufacturing device (1) according to one of the preceding claims, wherein the control device (19) is arranged to generate the intensity profile as a Gaussian, non-Gaussian, constant, asymmetric or distorted intensity profile. [4] Manufacturing device (1) according to one of the preceding claims, wherein the control device (19) is configured to additionally predetermine a shape of the beam region (15) by controlling the deflection device (13), wherein the control device (19) is in particular configured to predetermine a beam profile, comprising the shape of the beam region and the intensity profile in the beam region (15), by controlling the deflection device (13). [5] Manufacturing device (1) according to one of the preceding claims, wherein the control device (19) is configured to change the intensity profile and / or the shape of the beam region (15) during the manufacture of a component, in particular within the working region (9), by varying the at least one operating parameter. [6] Manufacturing device (1) according to one of the preceding claims, wherein the deflection device (13) is arranged in front of the scanner device (7) in the propagation direction of the energy beam (5). [7] Manufacturing device (1) according to one of the preceding claims, wherein the deflection device (13) has at least one acousto-optical deflector (21), preferably two acousto-optical deflectors (21) which are not oriented parallel to one another, preferably oriented perpendicular to one another. [8] Manufacturing device (1) according to one of the preceding claims, wherein the manufacturing device (1) has a separation mirror (23) behind the deflection device (13) and in front of the scanner device (7) in the propagation direction of the energy beam (5), which is designed to separate a zero-order partial beam from a first-order partial beam of the energy beam (5), wherein the separation mirror (23) is preferably arranged in the vicinity of an intermediate focus (31) of a telescope (33), in particular offset at a distance of 1 / 5 of the focal length from the intermediate focus (31) along the propagation direction. [9] Manufacturing device (1) according to one of the preceding claims, wherein the scanner device (7) has at least one scanner, in particular a galvanometer scanner, piezo scanner, polygon scanner, MEMS scanner, and / or a working head that can be displaced relative to the working area (9). [10] Manufacturing device (1) according to one of the preceding claims, wherein the beam generating device (3) is designed as a laser. [11] Manufacturing device (1) according to one of the preceding claims, wherein the manufacturing device (1) is designed for selective laser sintering and / or selective laser melting. [12] Method for generating a specific intensity profile of an energy beam (5) in a beam region (15) on a work area (9) of a manufacturing device (1) for the additive manufacturing of components from a powder material, wherein the specific intensity profile is generated by displacing the energy beam (5) within the beam region (15) and by predetermining at least one operating parameter for the energy beam (5), wherein the at least one operating parameter is selected from a group consisting of: a dwell time at a beam position (17) in the beam region (15), a beam position density distribution in the beam region (15), a frequency distribution of the beam positions (17) in the beam region (15), and an intensity influencing parameter for influencing the intensity of the energy beam (5) deflected to the beam positions (17). [13] Method according to claim 12, wherein additionally a specific shape of the beam region (15) is generated by specifying the at least one operating parameter. [14] Method according to one of claims 12 and 13, wherein the shape of the beam region (15) and / or the intensity profile is changed by varying the at least one operating parameter. [15] Method according to one of claims 12 to 14, wherein the intensity profile is additionally generated, preferably changed, by changing the intensity of the energy beam (5) provided by the beam generating device (3), in particular by controlling the beam generating device (3). [16] Method for the additive production of a component from a powder material, wherein a production device (1) according to one of claims 1 to 11 is used, and / or using a method according to one of claims 12 to 15, wherein preferably the shape of the beam region (15) and / or the intensity profile is / are changed during the production of the component, in particular within the working region, by varying the at least one operating parameter.

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