Method for generating construction job data for producing components using an additive manufacturing process and method for producing components using an additive manufacturing process, system and computer program

Abstract

The invention relates to a method for generating construction job data for producing components (9) using an additive manufacturing process, comprising: - Providing model data of components to be produced (9), - carrying out simulations for a respective component (9) relating to a post-treatment, wherein deformations on the components (9) which may occur due to the post-treatment of the components (9) are taken into account in the simulations, - Determining compensation data for a respective component (9) on the basis of the simulations, wherein the compensation data of a respective component (9) can be used to adapt a shape of the respective component (9) in order to compensate for the deformations, - Adjusting the model data of the components (9) based on the respective compensation data, - creating an arrangement pattern (21) based on the adapted model data of the components (9), and - Extracting the build job data from the created layout patterns (21). Furthermore, the invention relates to a method for producing components (9) as well as a system (1) and a computer program.

Description

[0001] The present invention relates to a method for generating construction job data for the production of components using an additive manufacturing process.

[0002] Furthermore, the invention relates to a method for producing components using an additive manufacturing process.

[0003] Furthermore, the invention relates to a system for producing components and a computer program.

[0004] For example, various parts or components can now be manufactured using an additive manufacturing process, i.e., a 3D printing process. For example, products immediately following an adjective saturation process or after the completion of a 3D printer printing process can be referred to as a green body or green compact. A green body or green compact specifically represents a blank that is typically further processed into a final product. This further processing can be, for example, thermal treatment or sintering.

[0005] For example, a "binder jetting" process can be used as an additive manufacturing process. This would involve producing an end product in a process chain. Geometries can be transferred to a 3D printer as CAD data, allowing the so-called green parts to be printed as a mixture of powder and a binder material. The mechanical properties of the printed green parts are insufficient, particularly for industrial applications or further industrial processing. For this purpose, the green parts are subsequently compacted in the sintering process as a post-treatment, whereby acceptable mechanical properties can be achieved. The compaction of the parts during sintering leads to shrinkage and / or deformation. The compaction and deformation of the parts depends on the green part properties.Green part properties vary depending on the orientation and position of the parts in the print chamber, as their properties are anisotropic and strongly depend on the print direction (print head or recoater build direction). One of the key prerequisites for accurate compensation is the estimation of the green part properties, particularly their density and dimensions. This means that a separate simulation is required for each new part position and orientation, which is usually very time-consuming. To avoid this, common practice is to only consider one orientation for part placement or nesting, for which compensation has already been performed using numerical simulations. Fixing the part orientation limits the ability to rotate the parts to create more space for denser nesting.This means fewer parts can be arranged in the pressure chamber or pressure chamber. Fewer parts in the pressure chamber mean lower process productivity.

[0006] Currently, the focus is either on a single orientation of the parts to ensure accurate manufacturing or nesting is performed without considering the alignment effects, resulting in a compromise in measurement accuracy.

[0007] When working with fixed orientations, the full potential of the print chamber capacity often remains unused, as an optimal distribution of the parts or components to maximize space utilization cannot be achieved. Neglecting the influence of orientation on the properties of green parts jeopardizes the dimensional accuracy of the components.

[0008] For example, US 2023 / 0 158 505 A1 discloses a method for producing an object through deep fabrication. A three-dimensional initial model of the target object can be received by a computer device. Based on the three-dimensional initial model of the target object, computer-based planning can be performed in order to manufacture the target object accordingly.

[0009] For example, US 2021 / 0 170 763 A1 discloses a method for coating a surface using a coating medium that can be produced using a multiple printhead. For this purpose, a two-dimensional or three-dimensional surface of an object can be coated or produced.

[0010] For example, US 2022 / 0 143 694 A1 further discloses a system and a method for adapting a geometry of a green body part.

[0011] An object of the present invention is to be able to generate construction job data of components to be produced in such a way that the components to be produced can be placed more efficiently for an additive manufacturing process in a placement process (“nesting”).

[0012] This problem is solved by a method, a system, and a computer program according to the independent patent claims. Useful further developments arise from the dependent patent claims.

[0013] One aspect of the invention relates to a method for generating construction job data for producing components using an additive manufacturing process, comprising the following steps: - In particular, providing model data of components to be produced, - In particular, carrying out simulations for a respective component to be produced concerning a post-treatment, in which the components to be produced can be post-treated following the additive manufacturing process, whereby deformations on the components to be produced, which may occur as a result of the post-treatment of the components to be produced, are taken into account in the simulations, - In particular, determining compensation data for a respective component to be produced on the basis of the simulations carried out, whereby with the compensation data of a respective component to be produced, a shape of the respective component to be produced can be adapted in such a way as to compensate for the deformations that may occur during post-treatment, - In particular, adapting the model data of the components to be created based on the respective compensation data, - In particular, creating an arrangement pattern based on the adapted model data of the components to be created, and - In particular, extracting the build job data from the created layout pattern.

[0014] The proposed method allows for efficient utilization of a printing area, build space, or print chamber in the additive manufacturing process, as the rotational and transactional degrees of freedom for the components can be improved during a nesting process, which in turn can increase overall productivity with regard to manufactured components. By determining the respective compensation data for a particular component to be produced, dimensional accuracy and thus the precision of the manufactured components after production can be improved. This is achieved in particular by taking into account the green part properties and component properties relevant for post-processing, such as sintering.Thus, during the nesting process, the shape of the components to be produced can be adjusted and positioned accordingly within the build space, taking into account the deformations due to post-processing, so that the quality of the end products is improved and the number of components to be produced using the additive manufacturing process can be increased. Using the compensation data, for example, compensation techniques for compensating for deformations during post-processing can be implemented in nesting algorithms to quickly update the shape of the components in relation to positions. Thus, for example, mathematical operations based on the compensation data can be used to determine the respective components for the current additive manufacturing process and / or for future manufacturing processes. This can reduce the need for time-consuming simulations.

[0015] With the help of the proposed method, in particular of the present invention, the productivity and in particular the effectiveness of additive manufacturing processes, such as a binder jetting process, can be increased. This is achieved in particular because the print chamber or the build space is utilized as much as possible with regard to the number of components to be manufactured, without losing the dimensional accuracy of the components. Due to the anisotropic properties of green parts, such as the components to be produced, which are present in different areas of the print chamber due to different print orientations and functionalities of 3D printing, for example, the parts experience different warpage behavior during post-processing, such as during sintering. For this purpose, the present method compensates the components separately using numerical simulations with a fixed or predetermined position direction.This reduces the permissible degrees of freedom in the distribution of parts within the build space, resulting in lower utilization of the print chamber. This allows for multiple components to be manufactured.

[0016] Additive or generative manufacturing is a manufacturing process that builds up or stacks components layer by layer. Printing components or green bodies using a 3D printer, for example, represents a generative process. With the help of additive manufacturing, material can be assembled, usually layer by layer, to create workpieces from 3D model data. The build job data specifies, in particular, where the component is to be created, for example, by melting the material.

[0017] The model data, for example, is computer-aided design (CAD) data. Based on the adapted model data, which can provide the shape, geometry, and / or orientation of the components to be created, the layout pattern can be created. Creating such an arrangement pattern can be referred to as "nesting." A computer or an implemented method, such as software, can be used to generate model data, in particular the arrangement pattern.

[0018] The method according to the invention can be applied to all additive manufacturing processes for plastic, metal or ceramic components, such as “SLS” (“Selective Laser Sintering”), “MJF” (“Three-Jet Material Deposition”), “Material Jetting”), “SLM” (“Selective Laser Melting”) or “Binder Jetting”).

[0019] For example, a proposed method may be a computer-implemented method.

[0020] In particular, with the help of the proposed method, a simulation can be carried out for a respective component to be produced in order to generate information with which statements about deformations and / or distortions of the components occur after a post-treatment process.

[0021] Post-treatment can, for example, be a further processing operation such as sintering. This involves sintering the components to be produced after they have been manufactured or printed, as the printed components, for example, are not yet stable enough. However, deformations can occur during post-treatment, meaning that the dimensional accuracy of the components can no longer be guaranteed. To compensate for this, appropriate compensation data can be determined or calculated based on the simulations performed. This can be transferred to the model data, for example using mathematical operations, so that the components can be manufactured in such a way that they have the desired geometry or shape and, in particular, dimensional accuracy after post-treatment.The compensation data can, for example, be applied to several components in the current manufacturing process or in future manufacturing processes.

[0022] The proposed method offers further advantages in that it allows for rapid transformation of the shape of components using transformation techniques and the use of mathematical transformation matrices, which can be extended with compensation parameters. Furthermore, the shape change of components can also be efficiently performed independently of the printing orientation. This is based on simulations in three directions, such as the spatial direction or the printing direction. In particular, a linear transformation of deviation vectors or deformation vectors is performed. Furthermore, rapid scaling of compensation geometries with respect to the component with respect to the printing position can be achieved.

[0023] In one embodiment, it is provided that in the simulations carried out for a respective component to be produced, any deformations occurring are considered in relation to at least three printing directions relating to the additive manufacturing process. In other words, several simulations can be carried out for a respective component to be produced, in particular for each component to be produced. Different simulations are carried out for each component in relation to at least three or more printing directions relating to the additive manufacturing process. The printing directions are to be understood in particular as those directions, in particular spatial directions (X, Y, Z), which can be used, for example, by a 3D printer to carry out an additive manufacturing process. The additive manufacturing process can thus be carried out in different printing directions.For example, different components can be manufactured in different printing directions.

[0024] Depending on the printing direction used to manufacture a component, its properties can change during post-processing, i.e., sintering. Thus, the deformation(s) of a component undergoing post-processing can depend on the printing direction used to create the respective component. Consequently, a simulation of the deformation of a component can be performed for each of the three printing directions, for example.

[0025] In one embodiment, it is provided that, based on the simulations performed for a respective component to be produced, the compensation data of a respective component to be produced are determined in such a way that the compensation data provide a first compensation with respect to its first printing direction of the at least three printing directions, a second compensation with respect to a second printing direction of the at least three printing directions, and a third compensation with respect to a third printing direction of at least three printing directions. In other words, such a data set can be provided for a respective component with which, depending on the printing direction in which the respective component is manufactured, the corresponding or appropriate compensation and, in particular, the corresponding compensation data can be assigned or used.This offers the advantage of providing comprehensive information regarding compensation, which can be used for later manufacturing processes or for other components.

[0026] For example, the first compensation can be compensation along the X direction, the second compensation along the Y direction, and the third compensation along the Z direction. This allows for the coverage of all possible spatial directions. Depending on how the components were printed or manufactured, i.e., in which reference direction they were printed or manufactured, the resulting deformations can be taken into account. This allows the model data to be adjusted so that the appropriate compensation can be performed for each component. Additionally, based on each compensation, the shape of the component to be produced can be adjusted in relation to the respective printing direction.For example, without the need for additional simulation using mathematical operations such as transformations, the respective compensation or calculated compensation can be used to adjust the model data accordingly. This allows the shape, geometry, position, and / or orientation of a particular component to be adjusted so that the components can now be reproduced in the printed state, and so that potential deformations, especially during post-processing, can be compensated for or even taken into account.

[0027] In one embodiment, a comparison result is determined for each of the three compensations in relation to the corresponding pressure direction, in which the deformations of the two pressure directions not taken into account in this compensation are compared with the pressure direction taken into account in this compensation. In other words, the three determined compensations for a respective component can be further processed. In this case, one of these compensations can be compared or contrasted with the other two compensations. For example, the first compensation can be considered here. In this case, a deformation can now be carried out in relation to the first spatial direction. Thus, deformations in relation to the first spatial direction or first pressure direction can be compensated.However, at least slight deformations can occur in the other two pressure directions. In other words, the first pressure direction is considered the reference or reference direction, and this is compared with the deformations or distortions or shrinkages with respect to the second and third pressure directions. Thus, with respect to a component to be produced, the three spatial directions present at a point, node, or area can be checked. At the base of the compensation data, each pressure direction can be considered a reference or zero point, allowing the fluctuations or changes with respect to the other two pressure directions or spatial directions to be observed or analyzed in comparison.

[0028] This can be done starting with a specific compensation, and thus starting with a specific pressure direction as a reference for comparison with the other two pressure directions. This allows a mathematical analysis of the respective component. The deformation properties of a specific point, node, or area of ​​the component can be examined.

[0029] In one embodiment, based on the comparison result of a respective component, at least one deformation vector or deviation vector can be determined with respect to the three pressure directions relating to the respective component to be produced, wherein the deformation vector is provided with the respective compensation times and taken into account when adapting the model data. Thus, a deformation vector can be generated or determined for a respective component to be produced and for certain predetermined or defined regions or points within the component to be produced. The deformation vector can therefore be used to determine which deformations or changes are to be expected at a point or region of a component.This can be used to incorporate adjustments to the model data without additional simulations, thus taking them into account when creating the layout pattern. The deformation vector allows the models or model data to be adjusted very easily, especially without additional simulations. Matrix transformations, matrices, operations, or other mathematical operations can be used for this purpose. In particular, transformation matrices can be created based on the deformation vectors, thus creating a transformation matrix that significantly simplifies the respective adjustment of current or future components.

[0030] In one embodiment, it is provided that, based on the adapted model data of the components to be produced, a respective position and / or orientation of the components to be produced is determined in a virtual construction space, which represents a real construction space in which the components to be produced are to be produced. This can be taken into account in particular when creating the arrangement pattern. The model data, the three-dimensional model data, can be adapted on a computer-based basis in such a way that, on the one hand, the deformations that can or do occur during post-treatment are compensated for and, by taking the respective printing direction into account, the components can be arranged as desired, as their degree of freedom can be increased. The virtual construction space is a computer-based, i.e. virtual, space that represents the real construction space, such as the print chamber of a 3D printer.This allows for the creation of the arrangement pattern, or "nesting," to be carried out computer-based. Based on the adjusted model data, which takes the compensations and printing directions into account, the components to be produced can be placed or arranged more efficiently. Above all, they can be arranged in different positions and / or orientations relative to one another, while still improving the dimensional accuracy of the final product.

[0031] Another aspect of terms, methods for producing components using an additive manufacturing process, comprising the following steps: - in particular applying a starting material to a support; - in particular, selective thermal action on the starting material by means of a directed energy source depending on the construction job data generated by a method of the previous aspect or an advantageous further development thereof; and - in particular post-treatment, in particular sintering, which is produced on the basis of selective thermal action.

[0032] This makes it possible to provide an efficient manufacturing process. The components can have greater dimensional accuracy. In particular, the scrap rate of non-fitting components can be reduced. Above all, productivity can be increased because the installation space can be utilized with more components while simultaneously improving dimensional accuracy. In one embodiment of the further aspect, it is provided that the components are manufactured using a free-jet binder application process as an additive manufacturing process. In other words, the components are manufactured using a "binder jetting process." With free-jet binder application, material is combined, usually layer by layer, to create workpieces from 3D model data. This involves, for example, a selective application of a liquid binder to bind powdered material.By applying heat, for example through a directed laser, the material or material mixture at the corresponding positions can be melted accordingly based on the build job data.

[0033] A further aspect of the invention relates to a system for carrying out a method according to the preceding aspect or an advantageous development thereof. The system may comprise a storage unit, an evaluation unit, and an output unit, wherein the system outputs the steps of the method according to the preceding aspect or an advantageous development thereof. In particular, the system just described can carry out the aforementioned method.

[0034] For example, the system can be a binder jetting system or a 3D printing system.

[0035] The system can be used to produce a component using an additive manufacturing process. The system comprises, in particular, printing material, such as the starting material, in the form of a binder with metal particles, for example. The printing material thus preferably contains the binder and several metal or plastic particles. The binder is preferably in the form of a liquid adhesive. The system comprises, for example, a powder bed on which the components can be manufactured layer by layer. With the additive manufacturing process, components can be manufactured layer by layer on the powder bed. For this purpose, the starting material can be layered onto the powder bed.

[0036] A further aspect of the invention relates to a computer program, including instructions which, when executed by a computer, cause the computer to execute a method according to the preceding aspects or an advantageous development thereof, and which can be loaded into a memory and executed by a processor. In particular, the aforementioned computer program can be used to generate construction job data, in particular the computer-implemented method.

[0037] For use cases or application situations that may arise during the method and which are not explicitly described here, it may be provided that, in accordance with the method, an error message and / or a request to enter user feedback is issued and / or a default setting and / or a predetermined initial state is set.

[0038] Advantageous embodiments of one aspect can be regarded as advantageous embodiments of all other aspects and vice versa.

[0039] The invention also includes further developments of the system according to the invention and the computer program according to the invention that have features already described in connection with the further developments of the method according to the invention. For this reason, the corresponding further developments of the system according to the invention and the computer program according to the invention are not described again here.

[0040] The invention also includes combinations of the features of the described embodiments.

[0041] Exemplary embodiments of the invention are described below. Shown are: Fig. 1 an exemplary system, in particular a 3D printing system, for performing an additive manufacturing process, such as binder jetting; Fig. 2 an exemplary arrangement of two components in a construction space of the system from Fig. 1; Fig. 3 an exemplary component which has been sintered after production and which has deformed during this process; Fig. 4 shows another exemplary component which, after sintering, has deformations which, in comparison to the illustrations in the Fig. 3 are more pronounced; Fig. 5 an optional possibility to calculate the deformations according to the Fig. 3 to compensate; Fig. 6 an exemplary possibility to calculate the deformations starting from the Fig. 4 to compensate; Fig. 7 schematically shows the installation space of the system Fig. 1, which is filled with various components that are differently positioned and oriented relative to each other by means of computer-based nesting; Fig. 8 a schematic view of a component in which a first compensation is performed with respect to the X-direction: Fig. 9 schematically shows the component starting from the Fig. 8, where compensation is made in the Y direction; Fig. 10 again starting from the Fig. 8 how this component can be compensated in relation to the Z-direction; Fig. 11 starting from the previous figures, how each of the compensations from the Fig. 8 to 10 is considered as a reference to compare with the other two; Fig. 12 starting from the Fig. 11 another example, where a comparison is made between XY directions; Fig. 13 starting from the Fig. 11 how a “Distortion Difference Vector DDV” can be calculated based on a comparison; and Fig. 14 another schematic view of the installation space of the system from the Fig. 1, where the adapted components can be positioned in such a way that possible translational deviations can be taken into account.

[0042] The exemplary embodiments explained below are preferred exemplary embodiments of the invention. In the exemplary embodiments, the described components each represent individual, independently considered features of the invention, which also further develop the invention independently of one another and are thus also to be considered as components of the invention, either individually or in a combination other than that shown. Furthermore, the described exemplary embodiments can also be supplemented by further features of the invention already described.

[0043] In the figures, functionally identical elements are provided with the same reference numerals.

[0044] In the Fig. Figure 1 schematically shows a system 1 for manufacturing components using an additive manufacturing process. System 1 can be, for example, a "three-jet binder application system." In other words, system 1 can be a 3D printing system or another device based on an additive manufacturing process. For printing or manufacturing components, system 1 has a build space 2 or a volume space. This build space 2 can be referred to, for example, as a print chamber or a print area in which components can be printed or manufactured using the additive manufacturing process.

[0045] Using system 1, material can be joined together, usually layer by layer, to create workpieces from 3D model data. Multiple layers 3 can be provided for this purpose. The components can thus be produced and hardened, for example, by the application of heat. For example, a starting material can be applied to produce components or workpieces. This starting material, which can be a liquid binder, can be applied here using a recoater. This recoater 4 can, for example, be moved back and forth in the Y direction. The layers 3 can, in turn, lie on top of one another in the Z direction. In order to be able to produce the respective components from the applied starting material, a printing device 5, such as a "print head", can be provided. This can, in turn, be moved back and forth in the X direction.By means of the pressure device 5, a selective thermal effect on the starting material can be carried out by means of a directed energy source, for example, so that, depending on the components to be manufactured, the material can be converted or processed accordingly in order to be able to produce the component to be manufactured.

[0046] For example, the system 1 for generating construction job data may comprise a storage unit 6, an evaluation unit 7 and / or an output unit 8.

[0047] In the Fig. Figure 2 shows a schematic representation of the build space 2. As already mentioned at the beginning, the system will manufacture components using an additive manufacturing mold. In particular, such components can be components or components 9 to be produced. The components 9 to be produced can be manufactured based on, for example, provided model data. The model data can be made available to the system 1, for example, so that, for example, build job data can be provided based on this model data. In particular, any number of components 9 can be manufactured in the build space 2.

[0048] For example, the components 9 can be manufactured with regard to or in relation to different printing directions. These printing directions can be defined in relation to the spatial directions (X, Y, Z). The component 10 can, for example, be printed with a first printing direction 11 (shown here as a small, shaded area). In contrast, the component 11 here, which is arranged upright compared to the component 11, can have been manufactured in relation to a second printing direction 13. In this case, the first printing direction 11 can be understood in relation to the X direction and the second printing direction 13 in relation to the Z direction. After a printing process, for example, the printed components 9 do not yet have a fixed structure or shape. This is subsequently achieved by post-treatment, such as a further processing step, such as sintering.This involves applying heat to harden the component, resulting in a dimensionally stable end product. However, this can result in deformation, shrinkage, distortion, and / or deformation, meaning that after this post-treatment, the components do not correspond to the actual or desired end product.

[0049] In the Fig. Figure 3, for example, shows the component that was manufactured and printed in relation to the first printing direction. This component 10 was then post-treated or sintered. As can be seen here, the component 10 exhibits deformations.

[0050] In the Fig. Figure 4 shows component 12 after post-treatment or sintering. This component was printed in the second printing direction. Compared to the Fig. 3 and the component 10 there, the component 12 shows even greater deformations

[0051] Such deformations influence not only the quality and in particular the dimensional accuracy of the components 9 but also the productivity and in particular the effectiveness of the actual manufacturing process and thus of the system 1. For this purpose, according to the invention, simulations are carried out on the basis of the model data of the components 9 to be produced. The simulations are carried out on the basis of the effects of the post-treatment or sintering. In other words, the simulation checks which deformations of the components can or do occur during or after the post-treatment. As a result, the components 9 can be adjusted on a computer basis and thus printed using the system 1 in such a way that the deformations that later occur during sintering can be taken into account. For this purpose, several simulations can be carried out for each component 9 to be produced.In this case, a simulation is performed, particularly with respect to the three-dimensional printing directions and, in particular, with respect to at least three spatial directions (X, Y, Z). Subsequently, a compensation file, i.e., compensation data for this component, can be determined or computer-generated for each component. Using this compensation data, it is possible to calculate for each component how the component 9 to be produced, and in particular its shape, is to be adapted or modified in order to account for the deformations occurring during post-processing by the manufacturer or during the design of the component 9.

[0052] For example, the Fig. 5 again starting from the Fig. 3 shows the component 10 after sintering. Based on the simulation, a first compensation can be determined or calculated for this component 10 using the compensation data. As shown in the Fig. 5, particularly in a side view, the first compensation model 14, which is to be understood in relation to the first pressure direction 11, has an adaptation form with respect to the component 10. Here, the regions 15 of the compensation model 14 and, in particular, the compensated representation, are adapted in their pre- or alignment or geometry such that they, in turn, compensate or compensate for the regions 16 or the deformation regions that are negatively influenced during sintering. As can be seen, the regions 15 have an opposite direction or orientation compared to the deformation regions 16, so that these deformations in the regions in the deformation regions 16 can be compensated or compensated for in order to in turn obtain or achieve the original component 10 as the end product.

[0053] With the compensation model 14 or with the compensation, for example, in this embodiment, the component 10 can be modulated and subsequently manufactured in such a way that the desired end product is ready after sintering.

[0054] In the Fig. 6 is again based on the Fig. 14, a second compensation model 18 is shown. The compensation model 18 can take into account the deformations of the component 12 after post-treatment. The second compensation model 18 has compensation areas 19 on the structure of the component 12, which in turn are opposite to the deformed areas of the non-compensated component 12, as shown in the Fig. 4. Thus, with the aid of the compensation media 18, the deformations occurring in the regions 20 can be compensated by designing or adapting the regions 19 opposite to the direction of deformation in the deformation regions 20.

[0055] Thus, with the present invention, the components 9 can be printed in such a way that, after sintering, they are designed in such a way that they correspond to the desired or required end product and are thus manufactured to exact dimensions.

[0056] In the Fig. 7 shows the construction space 2 again. In this example, several components 9 can be produced simultaneously using a printing process or an additive manufacturing process. These components can in turn be positioned differently, as shown in the Fig. 7. For each of these components 9 to be manufactured, a simulation can be carried out with regard to the subsequent deformations, so that these deformations are already taken into account in the computer-generated build job data for the components 9 to be manufactured, so that the components 9 can be arranged in different positions and / or orientations relative to one another. This arrangement can be carried out computer-based even before the printing process. For example, based on the simulations of the components 9 and the compensation data generated or created thereby, such as the compensation models 14, 8, the original model data for the components 9 to be produced can be adjusted, adapted, or changed. The model data can thus be adjusted or redesigned such that, as already explained above, the deformations can be taken into account.

[0057] Based on the adapted model data, an arrangement pattern 21 can be generated, for example. Nesting can be performed on a computer-based basis with the arrangement pattern 21, thus enabling a virtual environment. The arrangement pattern 21 can be arranged by placing and orienting the components 9 to be generated based on the adapted model data in a virtual installation space, which represents the real installation space 2. This can be done, for example, using the evaluation unit 7, in a computer-based or software-based manner. Thus, the computer-based determination of where and how the components should later be arranged can be carried out in advance.

[0058] For example, the arrangement pattern can be created using an algorithm such as the "nesting algorithm." This nesting allows the build space to be virtually populated in advance to achieve the highest possible utilization. By taking deformations into account during post-processing, the calculated compensation data can be used to more easily adapt, calculate, and design additional components or components to be created in the future. This can, for example, minimize costs and time-consuming simulations later on or in the future. By calculating the compensation data with regard to different printing directions or ambient light, the simulations can be carried out before nesting without the components having to have fixed orientations and positions.Since the components 9 can be compensated for with regard to deformation and this can be adapted to the model data, the components 9 can be arranged in the build space 2 and later manufactured in such a way that the influence on the anisotropic properties of the components 9 is no longer so strongly influenced by the orientation. Previous printing methods had the disadvantage that the positions of the components 9 influence the printing dimensions, but since with the present invention the components 9 are adapted in their shape based on the respective printing direction, the printing dimensions can now be designed more flexibly with regard to the printing directions.

[0059] Previously, it was the norm that if the orientation and / or position of a component had to be changed, new simulations or scaling factors had to be performed. Now, by simulating each component once and calculating the compensation data from it, the corresponding compensation can be retrieved from a database and adjusted accordingly to the model data, even if the components are realigned.

[0060] In the following, an exemplary embodiment is explained how the components 9 can be manufactured taking into account the deformations during post-treatment.

[0061] In the Fig. Figure 8 shows an exemplary representation of a component 22. This shows a side view of the geometry of component 92.

[0062] As already mentioned, at least three simulations can be performed per component, in this case component 22. The simulations can be performed with respect to parallelism to one of these spatial or pressure directions.

[0063] In the Fig. Figure 8 shows this simulation with respect to the first printing direction, i.e., parallel to the first printing direction 11, i.e., parallel to the direction of the movement sequence of the printing device 5. It shows how, in this embodiment, the shape of the component 22 is to be adapted or compensated with respect to the first printing direction 11. A first compensation 23 can now be determined based on the simulation performed. Thus, compensation can take place here if the component 22 was manufactured or printed with respect to the first printing direction.

[0064] In the Fig. 9, component 22 is again shown. Here, it is assumed that the simulation is based on a third printing direction 24, i.e., the Y-direction. Thus, this analysis can be performed in parallel with the movement sequence of the recoater 4. Here, again based on the simulations performed, a second compensation 25 is entered. This means that component 22 would have to be compensated if component 22 is to be manufactured in relation to the third printing direction 24.

[0065] In the Fig. 10 is again the case with respect to the second printing direction 13. Thus, the compensation can be determined based on the simulation if the component 22 was manufactured in the second printing direction. The simulation can be viewed in parallel with the printing direction in the Z direction, i.e., how the individual layers are arranged one above the other.

[0066] In other words, starting from the Fig. 8 to 10 compensations 23, 25, 26 for different spatial directions (X, Y, Z) are determined.

[0067] In order to make adjustments more efficiently for the respective components, especially for future components, without additional simulations, corresponding matrices or vectors can be created so that, using mathematical operations, the components can be adjusted based on the desired pressure direction with regard to subsequent post-processing. For this purpose, deformation vectors or "distortion difference vectors" can be generated or determined.

[0068] In the Fig. 11 is then based on the Fig. Figures 8 to 10 show how such a deformation vector can be determined. For this purpose, a reference or a reference point can first be defined. Fig. 11, the first compensation 23 is used as a reference. For each component, a comparison can be made with the other directions 11, 13, 24, starting from one of the compensations 23, 25, 26. In other words, component 22 can be considered as a reference; here, the compensation in the first pressure direction 11 can be considered as the zero position. Thus, a compensation is made in this direction. Now, it is assumed that deformations can occur with respect to the other two pressure directions 13, 24. Thus, a comparison is made here, starting from the specified reference, with respect to the deformations in the other directions, as in this example in the Fig. 11, a comparison is now first made starting from the first pressure direction (X direction) in relation to the Z direction, i.e., the second pressure direction 13. Thus, a comparison can be performed here so that, starting from the reference, the distortions or deformations can be determined in relation to the two other pressure directions or spatial directions. This allows a vector to be defined in relation to the X, Y, and Z directions. This can, in turn, be performed for any areas or points of the component 22.

[0069] In the Fig. 12 is now again based on the reference with respect to the first compensation 23, a comparison with the second composition 25, so here a comparison is made starting from the X-direction in relation to the Y-direction. In the Fig. 13, the determination of the deformation vector is explained again based on the previous figures. Here, the example from Fig. 11. A deformation vector can now be determined in an area 27 for comparison purposes. Thus, vectors can be determined for the various nodes, points, or regions of component 22.

[0070] For example, the deformation vector or distortion difference vector between the Z direction and X direction or the Y direction and X direction can have the vectors with the largest deviations between the Z direction and the Y direction. This is because in the Z production direction or in the Y production direction these are each perpendicular to the X direction. Therefore, for example, by means of linear interpolation between the largest deviation and the zero deviation, which is primarily the respective reference, in this example the X direction, in relation to an angle is possible. The angle is determined, for example, by the reference, in this example the X direction. Thus, a vector can be determined for the area 27 which lies in the XZ plane.

[0071] With trench 28, for example, an angle between X and Y could be defined or described.

[0072] In the Fig. Figure 14, for example, shows the build space 2 or the pressure chamber. Here, the component 22, or in particular several such components 22, can be manufactured. These components 22 can be adjusted in shape using the determined deformation vector, so that appropriate compensation can be performed. This can be taken into account when adapting the model data.

[0073] During a printing process, due to the way the printer works, green parts produced by system 1, such as component 22, may exhibit a certain deviation from the target geometry. This may impact the precise production of the final parts or end products. It can therefore be noted that there is no warping in the printing process, but only a pure translational dimensional differentiation. The translational dimensional deviations can be corrected using suitable scaling factors in all three directions. The values ​​of the translational dimensional deviations can be determined from previous tests or printing processes in relation to the respective positions of the parts or components 9. Such deviations 29 can be taken into account when aligning and / or positioning the components, particularly in the arrangement pattern 21.Thus, the construction job data regarding the components 9 to be produced, such as the component 22 here, can be extracted from the arrangement pattern 21 in such a way that the component 22 can be manufactured precisely and accurately.

[0074] In the following, the present invention is explained again in other words on the basis of the previous house tours.

[0075] For example, the compensated configurations can first be considered for each component 9. For all nodes or regions of the respective component 9, the wear difference vectors, such as the deformation vectors, can be calculated seamlessly and directly with respect to the respective orientation and position of the respective component 9. This can occur when a user or a mesh algorithm changes the orientation and / or alignment and / or position of a respective component 9 in the build space 2. These vectors can be saved. In particular, they can be saved in transformation matrices so that they can be retrieved for later printing processes and / or other components. These matrices can update the shape and dimensions of the compensated components using a "morphing technique" through appropriate stretching, squeezing, splitting, or rotating transformations.This leads to optimized nesting with fast and high degrees of freedom while simultaneously ensuring the dimensional accuracy of the components 9, especially after sintering. Furthermore, it should be noted that during rotation, the distortions caused by the deformation path should first be compensated. The shapes should be updated, and then the translational deformations can be applied to the deformed shapes or components. In mathematical terms, the rotation and shear components of the transformation matrices can be applied first, followed by the stretching and compression.

[0076] Thus, a rapid transformation of the shape of components 9 can be performed using a "morphing technique" using mathematical transformation matrices consisting of deformation vectors. Component shape changes can be performed independently of the printing orientation, as these occur in simulations in three spatial directions. A linear transformation of deviation vectors, such as the deformation vectors, is applicable. This allows for a rapid scaling of compensation geometries of components 9 with respect to a closer printing position or printing direction, efficiently and easily.

[0077] In other words, with the previous explanations, nesting optimization in binder jetting with rapid shape / dimensional changes of the parts can be achieved or carried out using transformation matrices and simulations.

[0078] Thus, component 30 (compare Fig. 7) using a deformation vector (distortion difference vector BBV) and a scaling for translational deviations. Component 31 (see Fig. 7) can, for example, be combined with the third compensation 26 and with a scaling for transaction deviations (Scale for Translation Dimension Deviation SfTDD). The component 32 (compare Fig. 7) may have been adapted analogously to component 31. Component 33 (compare Fig. 7) can be adjusted by means of the second or third compensation 25 and the SfTDD. The component 34 (compare Fig. 7) can be adjusted using DDV and SfTDD. Component 35 (see Fig. 7) can be adapted analogously to component 34. Component 36 (compare Fig. 7) can be adapted analogously to components 34 and 35. Component 37 (compare Fig. 7) can be adjusted with the first compensation 23 and the SfTTD. Component 38 can be adjusted analogously to components 34, 35, 36. Component 40 (compare Fig. 7) can be adjusted, for example, by means of the third compensation and the SfTDD. Thus, by means of the present invention and to any component 9, as described in the Fig. 7, regardless of their alignments and / or orientations and / or positions, these components can be adapted so that the installation space 2 can be optimally utilized for the production of multiple components 9, and at the same time, these components 9 can be manufactured to exact dimensions even after sintering. Thus, a final product can be optimized with respect to a component 9. List of reference symbols 1 system 2 Installation space 3 layers 4 recoaters 5 Printing device 6 storage unit 7 Evaluation unit 8 Output unit 9 Components to be produced 10 components 11 First printing direction 12 components 13 Second printing direction 14 Compensation model 15 compensation areas 16 deformation areas 17 Compensation process 18 Further compensation model 19 compensation areas 20 Deformation range 21 arrangement patterns 22 Component 23 First compensation 24 Third printing direction 25 Third Compensation 26 Second compensation 27 Area 28 graphics 29 Deviation 30 to 39 components QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 2023 / 0 158 505 A1

[0008] US 2021 / 0 170 763 A1

[0009] US 2022 / 0 143 694 A1

[0010]

Claims

[1] Method for generating construction job data for producing components (9) using an additive manufacturing process, comprising the following steps: - Providing model data of components to be produced (9), - Carrying out simulations for a respective component (9) to be produced relating to a post-treatment in which the components (9) to be produced can be post-treated following the additive manufacturing process, wherein deformations on the components (9) to be produced which may occur as a result of the post-treatment of the components (9) to be produced are taken into account in the simulations, - Determining compensation data for a respective component (9) to be produced on the basis of the simulations carried out, wherein the compensation data of a respective component (9) to be produced can be used to adapt a shape of the respective component (9) to be produced in such a way as to compensate for the deformations that may occur during the post-treatment, - Adapting the model data of the components to be created (9) based on the respective compensation data, - creating an arrangement pattern (21) based on the adapted model data of the components (9) to be produced, and - Extracting the build job data from the created layout patterns (21). [2] Method according to claim 1, wherein in the simulations carried out of a respective component (9) to be produced, deformations occurring in relation to at least three pressure directions (11, 13, 24) relating to the additive manufacturing process are considered. [3] Method according to claim 2, wherein, on the basis of the simulations carried out for a respective component (9) to be produced, the compensation data of a respective component (9) to be produced are determined in such a way that, with the compensation data, a first compensation (23) in relation to a first printing direction (11) of the at least three printing directions (11, 13, 24), a second compensation (26) in relation to a second printing direction (13) of the at least three printing directions (11, 13, 24) and a third compensation (25) in relation to a third printing direction (24) of the at least three printing directions (11, 13, 24) are provided, in particular, on the basis of a respective compensation (23, 25, 26), an adaptation of the shape of the respective component (9) to be produced in relation to a respective printing direction (11, 13, 24) can be carried out. [4] Method according to claim 3, wherein for each compensation of the three compensations (23, 25, 26) in relation to the corresponding pressure direction (11, 13, 24) a comparison result is determined by comparing the deformations of the two pressure directions (11, 13, 24) not taken into account in this compensation (23, 25, 26) with the pressure direction (11, 13, 24) taken into account in this compensation (23, 25, 26). [5] Method according to claim 4, wherein on the basis of the comparison result of a respective compensation (23, 25, 26) at least one deformation vector is determined in relation to the three pressure directions (11, 13, 24) relating to the respective component (9) to be produced, wherein the deformation vector is provided with the respective compensation data and is taken into account when adapting the model data. [6] Method according to one of the preceding claims, wherein on the basis of the adapted model data of the components (9) to be produced, a respective position and / or orientation of the components (9) to be produced in a virtual construction space, which represents a real construction space (2) in which the components (3) to be produced are to be produced, is determined. [7] Method for producing components (3) using an additive manufacturing process, comprising the following steps: - Applying a starting material to a support; - Selective thermal action on the starting material by means of a directed energy source depending on the build job data generated by a method of the preceding claims; and - post-treatment, in particular sintering, of the components produced on the basis of selective thermal action (9). [8] Method according to claim 7, wherein the components (9) are manufactured using a free jet binder application process as an additive manufacturing process. [9] System (1) for producing components (9) using an additive manufacturing process, comprising a storage unit (6), an evaluation unit (7) and an output unit (8), wherein the system (1) is designed to carry out the steps of the method according to claim 7 or 8. [10] A computer program comprising instructions which, when executed by a computer, cause the computer to carry out the method according to any one of claims 1 to 6, and which can be loaded into a memory unit (6) and executed by a processor.

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