DEVICE FOR THE GENERATIVE PRODUCTION OF A THREE-DIMENSIONAL OBJECT

Description

[0001] The invention relates to a method for the generative production of a three-dimensional object by successive layer-by-layer selective solidification of building material layers made of solidifiable building material.

[0002] Devices for the additive manufacturing of three-dimensional objects are known per se. Using appropriate devices, three-dimensional objects are constructed by successive, selective, layer-by-layer solidification of layers of solidifiable building material applied in a construction plane in the respective cross-sectional areas of the respective objects to be manufactured, using an energy or laser beam. The successive, selective, layer-by-layer solidification of the building material layers to be solidified is carried out on the basis of construction data describing the geometric shape, i.e., in particular, the layer-related cross-sectional geometries, of the respective three-dimensional object to be manufactured.

[0003] To generate the corresponding laser beams, a laser beam generation device is used, which is typically located outside a build or process chamber belonging to the device. A laser beam generated by a corresponding laser beam generation device is directed onto a build material layer to be selectively solidified via a beam deflection device, also known as a "scanner."

[0004] This configuration of corresponding devices is comparatively complex, particularly with regard to their technical design, and therefore requires further development.

[0005] WO 2014 / 199149 A1 discloses an additive manufacturing device which provides laser diodes.

[0006] US 2014 / 263209 A1 discloses an additive manufacturing facility.

[0007] US 2014 / 252687 A1 discloses an additive manufacturing device.

[0008] The invention is based on the object of providing an improved method for the generative production of a three-dimensional object, particularly with regard to a device for generating a laser beam that is comparatively simple in terms of plant technology.

[0009] The object is achieved by a method according to claim 1. The dependent claims relate to particular embodiments of the method.

[0010] The invention is defined by the appended claims. The device described herein generally serves for the additive or generative production of at least one three-dimensional object, e.g., a technical component or a group of technical components, by successively and selectively solidifying individual building material layers from a solidifiable building material using at least one laser beam generated by at least one device. The device can be a device for performing selective laser melting processes or selective laser sintering processes.

[0011] The successive, selective, layer-by-layer consolidation of a building material layer to be consolidated is carried out based on object-specific construction data. Corresponding construction data generally describe the geometric or geometric-constructive shape of the three-dimensional object to be produced using additive manufacturing (hereinafter referred to as "object"). Corresponding construction data can, for example, be or contain CAD data of the object to be produced.

[0012] The device comprises the functional components typically required for carrying out generative construction processes, i.e., in particular, a laser beam generation device, referred to as "device" for short, for generating a laser beam for the successive, layer-by-layer selective solidification of individual building material layers from a building material, i.e., in particular, a powdered metal, plastic, and / or ceramic material, and a coating device for forming building material layers to be solidified in a building plane. A building plane can be a surface of a support element of a support device, typically mounted so as to be movable (in the vertical direction), or an already solidified building material layer. In general, building material layers to be selectively solidified or selectively solidified are formed in a building plane.

[0013] The device can comprise at least one, typically several, laser diode element(s) arranged or arranged directly above the build plane, which is / are configured to generate a laser beam directed directly onto the build plane. The laser diode element(s) are typically arranged within a build or process chamber belonging to the device, in which generative build processes are carried out.

[0014] Alternatively or additionally, the device can comprise at least one, i.e. typically several, optical elements which are (optically) coupled to at least one laser diode element and can be arranged or arranged directly above the build plane, and which are designed to deflect a laser beam generated by the laser diode element directly onto the build plane. The laser diode element(s) are typically arranged outside a build or process chamber belonging to the device, in which generative build processes are carried out. An optical element can be designed as or at least comprise one focusing optics comprising one or more optical lens elements for focusing a laser beam onto the build plane. The (optical) coupling between an optical element and a laser diode element takes place via a light-guiding element, e.g. in the form of one or more fiber optic cables.Of course, it is possible to couple at least one optical element to several laser diode elements or to couple at least one laser diode element to several optical elements via suitable beam splitting elements.

[0015] Regardless of the arrangement of the laser diode elements and the corresponding provision of coupled optical elements, laser beams generated by the device typically impinge on the build plane at an angle of approximately 90° with respect to the build plane. The device can therefore be referred to or considered a "diode laser" because it comprises laser diode elements for generating laser beams or laser radiation. A laser diode element is understood to be a semiconductor element configured to generate laser radiation. The properties, ie in particular the optical properties, e.g. the wavelength, of the laser beam generated by a laser diode element depend, among other things, on the semiconductor material(s) used.The laser diode elements associated with the device can, for example, generate emitted laser powers in the range between 0.1 and 10 watts; of course, exceptions to this limit are conceivable.

[0016] The laser diode elements or optical elements belonging to the device are arranged directly above the build plane; typically, there are no other components, especially no optical mask components, between the laser diode elements or optical elements and the build plane. Accordingly, the laser beams are directed directly toward the build plane and impinge directly on it. It is not necessary to deflect the laser beams using a beam deflection device.

[0017] Overall, the device described herein for the additive manufacturing of three-dimensional objects offers a simplified design in terms of plant technology; thus, an improved device for the additive manufacturing of three-dimensional objects is provided.

[0018] The device can, as mentioned, comprise several, i.e. a plurality, of laser diode elements or optical elements. The laser diode elements or optical elements can cover at least part of the build plane, if necessary even the entire build plane, in terms of area. The build plane can typically be defined by a specific, for example rectangular, surface. The laser diode elements or optical elements are therefore located directly opposite at least a part, i.e. a partial (surface) area of ​​the overall (surface) area, of the build plane. It is of course also possible for the laser diode elements or optical elements to be located opposite a plurality of parts or partial areas of the build plane, which are either connected or not connected in terms of area. A part of the build plane covered in terms of area by corresponding laser diode elements or optical elements can be covered without any mandatory mechanical movement of the laser diode elements orSelectively expose optical elements relative to the build plane. Selective exposure is achieved by specifically controlling individual, several, or all laser diode elements to generate a laser beam with specific beam properties.

[0019] In this respect, it may be expedient for the laser diode elements or optical elements to completely cover the build plane, so that, in principle, any part or the entire area of ​​the build plane can be selectively exposed as needed without moving the device relative to the build plane. This represents a particular advantage over conventional devices, which typically comprise a beam deflection device for deflecting a generated laser beam and / or a movement mechanism for moving a laser beam generation device for selectively exposing a build plane. These devices, or the associated mechanisms of conventional devices, were structurally complex and sometimes problematic with regard to the realization of high-precision exposure processes.Another advantage over conventional devices is that "idle times" of the device due to the movement of a laser beam generating device can be reduced or avoided.

[0020] The laser diode elements or optical elements of the device can generally be arranged or arranged in any spatial arrangement relative to one another. The laser diode elements or a plurality of laser diode elements in the sense of a subset of a total number of laser diode elements present in the device, or the optical elements or a plurality of optical elements in the sense of a subset of a total number of optical elements present in the device, can be arranged in rows and / or columns in at least one common plane (typically parallel to the construction plane). An arrangement of laser diode elements or optical elements in connected rows and columns can be referred to as a "matrix-like arrangement", or "matrix" for short. A matrix thus comprises at least one row, typically a plurality of parallel rows, of (each) at least two laser diode elements oroptical elements and at least one column, typically several parallel columns of (each) at least two laser diode elements or optical elements. A corresponding column of laser diode elements or optical elements extends at an angle, in particular perpendicularly, to a corresponding row of laser diode elements or optical elements, and vice versa. A matrix-like arrangement of laser diode elements or optical elements can correspond to a pixel grid, as provided, for example, in liquid crystal display devices ("LCD displays"); the individual laser diode elements or optical elements correspond to the pixels of corresponding liquid crystal display devices.

[0021] At this point it should be noted that laser diode elements - again in accordance with the principle of a liquid crystal display device - can in principle be controlled individually or in groups to generate a laser beam with specific beam properties, i.e. in particular can be activated and / or deactivated. Activation or deactivation of a laser diode element can be understood as energizing the laser diode element; in an activated state the laser diode element is energized and generates a laser beam, and in a deactivated state it is not energized and does not generate a laser beam. Activation or deactivation of a laser diode element can also be understood as meaning that the laser beam that can be generated or generated via the laser diode element, e.g.by moving, in particular pivoting, the laser diode element, in an activated state of the laser diode element, the laser diode element is directed toward the build plane and in a deactivated state of the laser diode element, the laser diode element is directed away from the build plane. In an analogous manner, optical elements can also be directed toward the build plane and away from the build plane.

[0022] In addition to the described arrangement of corresponding laser diode elements or optical elements in a common plane, the laser diode elements or a plurality of laser diode elements can be arranged one above the other in the sense of a subset of a total number of laser diode elements available for the device, or the optical elements or a plurality of optical elements can be arranged one above the other in the sense of a subset of a total number of optical elements available for the device, in several planes (typically lying parallel to the construction plane). An arrangement of laser diode elements or optical elements in several planes above one another results in a particularly compact, optionally nested, arrangement of corresponding laser diode elements or optical elements. Of course, the arrangement of the laser diode elements oroptical elements in several levels one above the other are selected so that the laser beams can each be directed directly onto the build plane. The laser diode elements or optical elements arranged in respective levels one above the other are typically arranged with a certain spatial offset relative to one another. The laser beam generated by a laser diode element arranged in an upper level does not strike an element arranged in a lower level, but rather passes through a free space, e.g. in the form of a gap, a bore or another opening, between laser diode elements and / or optical elements arranged directly adjacent in a lower level onto the build plane. Analogously, the laser beam deflected by an optical element arranged in an upper level does not strike an element arranged in a lower level, but rather passes through a free space, e.g.in the form of a gap, a bore or another opening, between laser diode elements and / or optical elements arranged directly adjacent to one another in a lower plane onto the construction plane.

[0023] Irrespective of the arrangement of laser diode elements or optical elements in one or more superimposed planes, the laser diode elements or a plurality of laser diode elements can be arranged or positioned in the sense of a subset of a total number of laser diode elements present in relation to the device, or the optical elements or a plurality of optical elements can be arranged or positioned in the sense of a subset of a total number of optical elements present in relation to the device, with regard to an outer and / or inner contour, possibly cross-sectional, of an object to be produced. The mentioned aspect of the fundamentally arbitrary spatial arrangement of laser diode elements or optical elements relative to one another makes it possible to arrange laser diode elements or optical elements with regard to a specific outer and / or inner contour of an object to be produced, such that the arrangement of the laser diode elements orOptical elements enable exposure of the outer and / or inner contour of the object to be manufactured. This applies regardless of the geometric shape of the object to be manufactured, since the laser diode elements or optical elements can be arranged with respect to the geometric shape of an object to be manufactured in such a way that they cover the maximum or minimum spatial dimensions of the object to be manufactured, particularly cross-sectional dimensions.

[0024] As will be described below in connection with a suitable holding device on or in which laser diode elements or optical elements can be arranged, it is possible for laser diode elements or optical elements to be arranged or arranged in groups preconfigured in a specific spatial arrangement with respect to a specific outer and / or inner contour of an object to be manufactured. Of course, a preconfigured group can also comprise laser diode elements and optical elements. If an object to be manufactured has a triangular cross-section, for example, a preconfigured group of laser diode elements has laser diode elements in a corresponding triangular arrangement. Analogously, a preconfigured group of optical elements has optical elements in a corresponding triangular arrangement.Since several objects with geometrically different shapes can be produced in a generative construction process, several differently preconfigured groups of laser diode elements or optical elements can of course also be present.

[0025] Individual, multiple, or all laser diode elements can be variable in at least one parameter relating to the beam properties of the laser beam generated thereby, in particular in their input and / or output power. Individual, multiple, or all laser diode elements can thus be "dimmable" in a similar way to a dimmable LED. Accordingly, laser beams with different beam properties, i.e., different energy density, intensity, etc., can be generated via a laser diode element that can be varied in at least one parameter relating to the beam properties, e.g., by varying the input and / or output power. In the case of multiple laser diode elements that can be varied in at least one parameter relating to the beam properties, specific total beam energy profiles can thus be formed when multiple laser beams are generated simultaneously.For example, consider a row-like arrangement of several laser diode elements or optical elements, where the laser diode elements are controlled or their output power is varied in such a way that a total beam energy profile with a specific geometric shape is obtained. For a Gaussian total beam energy profile, centrally arranged laser diode elements or optical elements are supplied with a higher power than laser diode elements or optical elements arranged at the edges. Of course, a Gaussian total beam energy profile is only to be understood as an example; in principle, total beam energy profiles of any two- or three-dimensional geometric shape can be generated by appropriately controlling the laser diode elements.

[0026] A row-like or column-like arrangement of a plurality of laser diode elements, or of optical elements coupled to such laser diode elements, whose parameters can be varied in at least one respect to the beam properties of the laser beam generated thereby, further enables the laser diode elements to be controlled or their output power to be varied in such a way that a dynamic overall beam energy profile is produced that can be moved or moved along the build plane, possibly back and forth, corresponding to a wavefront along the row-like or column-like arrangement of the laser diode elements or optical elements. For this purpose, the laser diode elements are controlled in a manner analogous to an LED display comprising several LEDs for the moving display of alphanumeric symbols. The laser diode elements or optical elements correspond to the LEDs associated with the LED display.The total beam energy profile can have a specific geometric shape, e.g. Gaussian, by controlling the laser diode elements as described.

[0027] The principles can, of course, also be applied to a matrix-like arrangement of multiple laser diode elements or optical elements. In this case, stationary or moving total beam energy profiles with at least partially identical, similar, or different cross-sectional profiles—generally, total beam energy profiles of any three-dimensional geometric shape—can be realized.

[0028] In general, individual, multiple, or all laser diode elements can differ in at least one parameter relating to the beam properties of the laser beam generated by them. The formation of specific two- or three-dimensional total beam energy profiles with at least partially identical, similar, or different cross-sectional profiles can thus also be achieved by laser diode elements that differ in at least one parameter relating to the beam properties of the laser beam generated by them, i.e., for example, in their input and / or output power.For example, a row-like or column-like arrangement of several laser diode elements can be considered, which differ in at least one parameter relating to the beam properties of the laser beam that can be generated by them, wherein the laser diode elements are arranged in such a way that a specific total beam energy profile with a specific geometric shape results. With a Gaussian total beam energy profile, centrally arranged laser diode elements have, for example, a higher output power than laser diode elements arranged at the edges.Of course, a Gaussian total beam energy profile is only to be understood as an example here; in principle, total beam energy profiles of any two-dimensional geometric shape can also be generated using a corresponding arrangement of laser diode elements that differ in at least one of the parameters relating to the beam properties of the laser beam that can be generated by them. The same applies, of course, to a row- or column-like arrangement of several optical elements.

[0029] Laser beams generated by correspondingly different laser diode elements can also be used to realize different functions, i.e., in particular, pre-tempering of building material layers (still) to be solidified and / or post-tempering of already solidified building material layers. For example, at least one first laser diode element, optionally also a group of first laser diode elements, can be configured to generate a laser beam for solidifying building material layers to be solidified, and at least one further laser diode element, optionally also a group of further laser diode elements, can be configured to generate a laser beam for pre-tempering of building material layers to be solidified and / or for generating a laser beam for post-tempering of already solidified building material layers.A laser beam generated for the consolidation of building material layers typically has a higher energy (density) than a laser beam generated for pre- or post-tempering of building material layers to be consolidated or already consolidated.

[0030] It has already been mentioned that the laser diode elements or optical elements can be conveniently arranged or arranged on a holding device. Such a holding device, typically frame-like, comprises a number of predeterminable or predetermined arrangement positions, at or in which at least one laser diode element or at least one optical element can be arranged. Such a holding device can have any basic shape. The basic shape of the holding device is typically dimensioned such that the holding device can be readily arranged in a construction or process chamber of the device.

[0031] The laser diode elements or optical elements can be arranged or positioned in such a holding device at predeterminable or predetermined positions, in particular in a detachable manner (without damage or destruction), as needed. A detachable connection can be useful, for example, in the event of a defect in a laser diode element or an optical element, since the defective laser diode element or optical element can be easily removed from the holding device and replaced.

[0032] In this context, a detection device for detecting a defective laser diode element or a defective optical element can be useful, which, upon detection of a defective laser diode element or optical element, e.g. acoustically and / or optically, outputs information relating to a defective laser diode element or optical element. The information can contain details about technical specifications, e.g. type, of the defective laser diode element or optical element, the exact nature of the defect, the arrangement or position of the defective laser diode element or optical element on or in the holding device, etc. Furthermore, an exchange device which interacts with the detection device for the partially or fully automated exchange of defective laser diode elements or defective optical elements is conceivable, so that the device always has a complete number of laser diode elements oroptical elements. A corresponding exchange device comprises a number of gripper elements for gripping laser diode elements or optical elements during the exchange. The exchange device can be designed, for example, as a single- or multi-axis robot device or at least comprise one such device.

[0033] By arranging laser diode elements or optical elements as required at predeterminable or predetermined arrangement positions of the holding device, it is possible for laser diode elements or optical elements to be arranged or be arranged as required at predeterminable or predetermined arrangement positions of the holding device in groups preconfigured with regard to a, possibly cross-sectional, outer and / or inner contour of an object to be produced in a specific spatial arrangement relative to one another. Thus, in connection with the generative production of an object with a specific outer and / or inner contour, it is possible to have at least one preconfigured group of laser diode elements or optical elements formed from laser diode elements or optical elements arranged in a specific spatial arrangement relative to one another.to prepare optical elements, to connect them to the holding device for carrying out the generative production of the object, i.e. to insert them into the holding device, and to remove them from the holding device after the production of the object or to exchange them for a subsequent production of another object with a different outer and / or inner contour for another group of laser diode elements or optical elements preconfigured in a specific spatial arrangement with regard to the outer and / or inner contour of the other object.

[0034] Respective preconfigured groups of laser diode elements or optical elements can therefore generally be assigned to or associated with an object with a specific geometric shape, i.e., in particular, with a specific outer and / or inner contour. Respective preconfigured groups of laser diode elements or optical elements can be (temporarily) stored in a warehouse while maintaining the arrangement of the laser diode elements or optical elements and used as often as desired for the additive manufacturing of the objects associated with them. It is of course also possible to reconfigure a preconfigured group of laser diode elements or optical elements with respect to the geometric shape of another object by rearranging individual, several, or all of the laser diode elements or optical elements in a manner analogous to a type case ("type case principle").

[0035] To arrange the laser diode elements on or in the holding device, the holding device can comprise a number of receiving means for receiving at least one laser diode element or optical element. The number of receiving means typically corresponds at least to the number of laser diode elements or optical elements of the device. The receiving means can comprise certain connecting elements which interact with corresponding mating connecting elements arranged or formed on the laser diode elements or optical elements to form a (positionally) stable, (damage- or destruction-free) detachable or non-detachable connection between the laser diode elements or optical elements and the holding device. Through the interaction of corresponding connecting elements and corresponding mating connecting elements, for example, a positive and / or non-positive connection can be produced; the connecting elements can, for example,as form-fitting and / or force-fitting elements, e.g., plug-in elements such as plug-in pins or corresponding plug-in receptacles, and / or locking / snap-fitting elements such as locking / snap-fitting projections or corresponding recesses, and / or screw / threaded elements such as screw or threaded bolts or corresponding screw or threaded receptacles, etc. The mating connecting elements can be designed as corresponding form-fitting and / or force-fitting elements. Laser diode elements or optical elements can of course also be connected to the holding device in a material-to-material manner, e.g., by bonding.

[0036] The holding device can be mounted so as to be movable in at least one degree of freedom of movement relative to the build plane. The movement of the holding device takes place via a suitable drive and / or guide device, i.e. in particular an (electric)motor-driven drive and / or guide device which can be coupled or is coupled to these. The movement of the holding device makes it possible to move the holding device, together with the laser diode elements or optical elements arranged on or in it, relative to the build plane to be exposed with regard to a specific exposure situation. The movement of the holding device can include translational degrees of freedom of movement along at least one translation axis and / or rotational degrees of freedom of movement about at least one rotation axis. The movement of the holding device can therefore be, for example, a linear, rotary, tilting or pivoting movement.Of course, combined movements in several different degrees of freedom are possible.

[0037] The movement of the holding device can occur simultaneously with the exposure of the build plane. The holding device can also be moved in connection with the exposure of the build plane with different degrees of freedom of movement or in different movement paths relative to the build plane. In this way, different hardening structures, e.g. weld seams, can be formed in the build material layer to be hardened. In this way, residual stresses arising during the process in the object to be manufactured can be reduced, which has a positive effect on the quality of the object to be manufactured. For the example of a holding device with laser diode elements or optical elements arranged on it or therein in a row-like or column-like arrangement, the holding device can initially be moved, e.g. along a first movement path defined by a first, e.g. linear, movement axis across the build plane and subsequently along a further, e.g.A further movement path defined by a linear movement axis can be moved across the build plane. The further movement path can, for example, be angular, particularly orthogonal, to the first movement path. The same can, of course, also be applied to laser diode elements or optical elements arranged differently, e.g., in a matrix-like manner.

[0038] In the case where the holding device is not mounted so as to be movable relative to the build plane, the device expediently comprises a plurality of laser diode elements or optical elements which cover at least a part or a partial area of ​​the build plane, in particular the entire build plane. In particular, when the build plane is completely covered by a corresponding arrangement of laser diode elements or optical elements, it is not necessary to move the holding device together with the laser diode elements or optical elements arranged thereon or therein relative to the build plane with regard to a specific exposure situation. In this case, no drive and / or guide devices which can be coupled or are coupled to the holding device are required, which could increase the system or control technology structure of the device.

[0039] Regardless of the movable or immovable mounting of the holding device relative to the build plane, at least one laser diode element or at least one optical element can (also) be arranged or disposed on or in the holding device in at least one degree of freedom of movement relative to the holding device and thus also relative to the build plane. By moving individual, several or all laser diode elements or optical elements relative to the holding device, it is possible, for example, to move the laser diode elements or optical elements relative to the building plane with regard to a specific exposure situation. It is also possible to move, i.e. in particular to tilt or pivot, individual, several or all laser diode elements or optical elements into a deactivated state in which a respective generateable or generated laser beam is directed away from the build plane.The movement of a laser diode element or an optical element can include translational degrees of freedom along at least one translational axis and / or rotational degrees of freedom about at least one rotational axis. The movement of a laser diode element or an optical element can thus be, for example, a linear, rotary, tilting, or pivoting movement. Of course, combined movements with several different degrees of freedom are also possible here.

[0040] The movement of the laser diode elements or optical elements can also take place simultaneously with the exposure of the build plane. Individual, several or all laser diode elements or optical elements can, in connection with the exposure of a specific build plane, also be moved with different degrees of freedom of movement or in different movement paths relative to the build plane. In this way, different hardening structures, e.g. weld seams, can be formed in the build material layer to be hardened. In this way, residual stresses that arise during the process in the object to be manufactured can be reduced, which has a positive effect on the quality of the object to be manufactured. Individual, several or all laser diode elements or optical elements can initially be moved, e.g. along a first movement path defined by a first, e.g. linear, movement axis across a build plane and subsequently along a movement path defined by further, e.g.A further movement path defined by a linear movement axis can be moved across the build plane. The further movement path can, for example, be at an angle, particularly orthogonal, to the first movement path.

[0041] A coating device, typically associated with the device, can be arranged or configured on the holding device for forming a layer of building material to be consolidated. This represents a particularly compact option for integrating a coating device into the device. To form a layer of building material, the coating device arranged or configured on the holding device can be moved relative to the building plane, for example, together with the movably mounted holding device.

[0042] The coating device can also be expediently arranged or configured on the holding device so that it can move relative to the holding device in at least one degree of freedom. For moving the coating device relative to the holding device and thus also relative to the build plane, drive and / or guide devices that can be coupled or are coupled to the coating device, in particular (electric) motor-driven, can be provided. In this case, in particular, it is possible to perform coating processes and exposure processes simultaneously; expediently, only those parts of the build plane in which a build material layer has already been formed by the coating device are exposed.

[0043] The device can comprise a detection device for detecting the temperature and / or the melt (pool) characteristics of a building material layer to be solidified, a layer that is currently solidifying, or a layer that has already fully solidified. The detection device can be designed as a pyrometer or at least comprise such a pyrometer. The detection device can also be arranged or formed on the holding device. This represents a particularly compact option for integrating a corresponding detection device into the device. The temperature values ​​or melt (pool) characteristics detected by the detection device can be used as the basis for pre-tempering a building material layer to be solidified or for post-tempering an already solidified building material layer.

[0044] The detection device can also be expediently arranged or configured on the holding device so that it can move relative to the holding device in at least one degree of freedom. For moving the detection device relative to the holding device and thus also relative to the build plane, drive and / or guide devices that can be coupled or are coupled to the detection device, in particular (electric) motor-driven, can be provided. In this case, in particular, it is possible to perform detection processes and exposure processes simultaneously; in this case, parts of the build plane that are yet to be solidified or have already solidified can be exposed. The exposure parameters can be adjusted depending on the detected temperature or melt (pool) characteristics.

[0045] The device can further comprise at least one evaluation device for, in particular optically, evaluating the surface quality and / or the melt (pool) characteristics of a build material layer to be solidified, a layer that is currently solidifying, and / or a layer that has already solidified. The evaluation device can be designed as a camera or at least comprise such a camera. The evaluation device can also be arranged on or in the holding device, in particular so as to be movable in at least one degree of freedom relative to the holding device. In this case in particular, it is possible to carry out coating processes, exposure processes, and evaluation processes simultaneously; expediently, only parts of the build plane in which a build material layer has already been formed and exposed are evaluated.

[0046] The holding device can comprise a plurality of holding device segments, wherein at least two holding device segments are arranged to be movable relative to the construction plane in at least one degree of freedom of movement and / or relative to one another in at least one degree of freedom of movement. The movement of the holding device segments can include translational degrees of freedom of movement along at least one translation axis and / or rotational degrees of freedom of movement about at least one rotation axis. The movement of a holding device segment can thus be, for example, a linear, rotary, tilting, or pivoting movement relative to the construction plane and / or relative to at least one other holding device segment.The movement of holding device segments in at least one degree of freedom of movement relative to the construction plane and / or in at least one degree of freedom of movement relative to one another can take place alternatively or in addition to a movement of the entire holding device relative to the construction plane.

[0047] A number of laser diode elements or optical elements are typically arranged on at least one first holding device segment, e.g. in a row-like and / or column-like arrangement, for illuminating a build material layer to be solidified. A further number of laser diode elements or optical elements can be arranged on at least one further holding device segment for pre-tempering a build material layer to be solidified and / or for post-tempering an already solidified build material layer. Alternatively or additionally, at least one further functional component of the device can be arranged on at least one further holding device segment. Such a further functional component can be, for example, an application orDosing device for applying a specific amount of building material to a building level, a coating device for forming a building material layer to be solidified, an evaluation device for the, in particular optical, evaluation of the surface quality or the melt (pool) characteristics of a building material layer to be solidified, a layer that is (currently) solidifying and / or a solidified layer, a detection device for detecting the temperature and / or the melt (pool) characteristics of a building material layer to be solidified, a layer that is (currently) solidifying or an already solidified layer, etc.

[0048] A specific example of a holding device comprising multiple holding device segments comprises four holding device segments arranged, e.g., in a cross-like manner, which are movable individually, in groups, or as a whole relative to the build plane and / or individually or in groups relative to one another. An application or dosing device can be arranged on a first holding device segment, a coating device can be arranged on a second holding device segment, a number of laser diode elements or optical elements for illuminating a build material layer to be solidified can be arranged on a third holding device segment, and a detection device for detecting the temperature and / or the melt (pool) characteristics can be arranged on a fourth holding device segment.

[0049] Another concrete example of a holding device comprising a plurality of holding device segments comprises six holding device segments arranged, e.g., in a cross-like manner, which are movable individually, in groups, or as a whole relative to the build plane and / or individually or in groups relative to one another. An application or dosing device can be arranged on a first holding device segment, a coating device can be arranged on a second holding device segment, a detection device for detecting the temperature and / or the melt (pool) characteristics can be arranged on a third holding device segment, and a number of laser diode elements oroptical elements for exposing a building material layer to be solidified, a detection device for detecting the temperature and / or the melt (pool) characteristics can be arranged on a fifth holding device segment, and an evaluation device for, in particular optical, evaluation of the surface quality and / or the melt (pool) characteristics can be arranged on a sixth holding device segment.

[0050] Of course, all functional components of the device that are mounted so as to be movable in at least one degree of freedom of movement, i.e., for example, the holding device or corresponding holding device segments, the coating device, the detection device, the evaluation device, can be movable via one or more common, in particular (electro)motor, drive and / or guide device(s).

[0051] The device can comprise a simulation device which is set up to simulate at least one object-related object parameter of the object to be additively produced or manufactured, which object can change during the implementation of a generative construction process. The simulation device can, on the basis of or taking into account various information relevant to the respective object parameter to be simulated, such as information about the building material used during the implementation of the generative construction process, information about various properties, e.g. density, geometry, etc., of the object to be additively produced or manufactured, etc., carry out a simulation of at least one object-related object parameter which can change during the implementation of a generative construction process with the device.The simulation facility implemented in hardware and / or software must be equipped with suitable simulation algorithms.

[0052] A corresponding object-related object parameter that changes during the implementation of a generative construction process can be, for example, the heat flow through the object to be produced or manufactured during the implementation of a generative construction process and / or the temperature or the temperature distribution of the object to be produced or manufactured, generally certain thermal properties of the object to be produced or manufactured. Alternatively or additionally, it is also conceivable that the object-related object parameter could be mechanical loads, in particular stresses, that may arise in the three-dimensional object to be produced or manufactured during the implementation of a generative construction process.

[0053] The device expediently comprises a control device which is designed for the targeted control of the device, i.e. in particular for the targeted control of individual, multiple or all laser diode elements for the respective generation of a laser beam with specific beam properties. The control device implemented in hardware and / or software can thus generate corresponding control information on the basis of which a targeted control of individual, multiple or all laser diode elements takes place for the respective generation of a laser beam with specific beam properties. As mentioned, individual, multiple or all laser diode elements can be varied in at least one parameter relating to the beam properties of the laser beam that can be generated via them, in particular in their input and / or output power.In particular, it is possible for individual, several, or all laser diode elements to be "dimmable," similar to a dimmable LED. Accordingly, laser beams with different beam properties, such as different energy densities, intensities, etc., can be generated using a laser diode element that can be varied in at least one parameter relating to the beam properties, e.g., by varying the input and / or output power.

[0054] The control device is expediently configured for the targeted control of individual, multiple, or all laser diode elements for the respective generation of a laser beam with specific beam properties based on the object-related object parameter or at least one object-related object parameter simulated by the simulation device. Thus, with appropriate control by the control device, the device can be configured to set or maintain at least one corresponding object-related object parameter to a specific value by appropriately controlling individual, multiple, or all laser diode elements for the respective generation of a laser beam with specific beam properties.For example, the device can be configured, with appropriate control by the control device, to generate and / or maintain a specific heat flow through the object to be produced or manufactured by additive manufacturing, or a specific temperature (distribution) in the object to be produced or manufactured by additive manufacturing, by appropriately controlling individual, several, or all laser diode elements to generate a laser beam with specific beam properties (as part of the generative construction process). In other words, it is possible to simulate the object beforehand and, for example, to individually control the power of the individual diodes according to the heat flow. In this way, the structural properties of the object to be produced or manufactured can be specifically and positively influenced.

[0055] The invention relates to a method for the additive manufacturing of at least one three-dimensional object by successively selectively solidifying individual building material layers made of solidifiable building material using at least one laser beam according to claim 1. The method can be a selective laser melting (SLM) or a selective laser sintering (SLS) process. The method is characterized in that a device as described is used for the additive manufacturing of at least one three-dimensional object. Therefore, all statements relating to the device apply analogously to the method.

[0056] The invention is explained in more detail using exemplary embodiments in the drawing figures.

[0057] Showing: Fig. 1 - 12 each show a schematic diagram of a device for the generative production of a three-dimensional object according to an embodiment.

[0058] Fig. 1 shows a schematic diagram of a device 1 according to an embodiment.

[0059] The execution according to Fig. 1 does not fall within the scope of the claims. The device 1 serves for the generative production of a three-dimensional object 2, i.e., for example, a technical component or a group of technical components, by successively and selectively solidifying building material layers from a solidifiable building material 3 by means of at least one laser beam 5 generated by a device 4 (laser beam generating device).

[0060] The solidifiable building material 3 can be a metal powder (mixture), e.g. an aluminum powder, and / or a plastic powder (mixture), e.g. a polyetheretherketone powder, and / or a ceramic powder (mixture), e.g. an aluminum oxide powder.

[0061] Respective build material layers to be solidified are formed in a build chamber 8 of the device 1 by means of a coating device 7, which is movably mounted, as indicated by the horizontally oriented double arrow 6. A protective gas atmosphere, e.g., an argon or nitrogen atmosphere, typically prevails in the build chamber 8. The successive, layer-by-layer, selective solidification of respective build material layers to be solidified occurs in such a way that laser beams 5 generated by the device 4 are selectively directed onto specific regions of the respective build material layers to be solidified, corresponding to the respective layer-related cross-sectional geometries of the object 2 to be produced.

[0062] The device 4 comprises a plurality of laser diode elements 10 for generating laser beams 5, each of which is configured to generate a laser beam 5 directed directly onto the build plane 9. Laser beams 5 generated by the device 4 typically impinge on the build plane 9 at an angle of 90° with respect to the build plane. The device 4 can be referred to or considered a "diode laser" insofar as it comprises laser diode elements 10 for generating laser beams 5 or laser radiation. The laser diode elements 10 associated with the device 4 can, for example, generate emitted laser powers in the range between 0.1 and 10 watts.

[0063] The device 4 is arranged directly in the build chamber 8. The laser diode elements 10 are arranged directly above the build plane 9; there is no further component, in particular no optical mask component, between the laser diode elements 10 and the build plane 9. Accordingly, the laser beams 5 generated or capable of being generated by the laser diode elements 10 are directed directly toward the build plane 9 and impinge directly on the build plane 9. It is not necessary to deflect the laser beams 5 generated or capable of being generated by the laser diode elements 10 using a beam deflection device.

[0064] In the Fig. 1 In the embodiment shown, the laser diode elements 10 are arranged in a matrix-like arrangement ("matrix"). This refers to an arrangement of the laser diode elements 10 in several parallel rows and columns. The matrix thus comprises several parallel rows of several laser diode elements 10 and several parallel columns of several laser diode elements 10. The rows and columns lie in a plane parallel to the construction plane 9. The columns extend at an angle, in particular perpendicular, to the rows and vice versa. The matrix-like arrangement of laser diode elements 10 corresponds to a pixel grid, as provided, for example, in liquid crystal display devices ("LCD displays"); the individual laser diode elements 10 correspond to the pixels of corresponding liquid crystal display devices.

[0065] The matrix-like arrangement of laser diode elements 10 extends completely across the build plane 9. The laser diode elements 10 are thus located directly opposite the entire surface of the build plane 9 and completely cover the build plane 9. Since the laser diode elements 10 completely cover the build plane 9, in principle any part of the entire surface of the build plane 9 can be selectively exposed as needed without moving the device 4 relative to the build plane 9. The selective exposure of the build plane 9 is achieved by targeted control of individual, several, or all of the laser diode elements 10 to generate a laser beam 5 with specific beam properties. For this purpose, a control device 11 is provided, which is coupled to the device 4 and can be arranged inside or—as shown in dashed lines—outside the build chamber 8.

[0066] The laser diode elements 10 can - in accordance with the principle of a liquid crystal display device - generally be controlled individually, in groups or as a whole to respectively generate a laser beam 5 with specific beam properties, i.e. in particular can be activated and / or deactivated. Activation or deactivation of a laser diode element 10 can be understood as energizing the laser diode element 10; in an activated state, the laser diode element 10 is energized and generates a laser beam 5, and in a deactivated state, it is not energized and does not generate a laser beam 5. Activation or deactivation of a laser diode element 10 can also be understood as meaning that the laser beam 5 that can be generated or generated via the laser diode element 10, e.g.by moving, in particular pivoting, the laser diode element 10, in an activated state of the laser diode element 10 is directed towards the construction plane 9 and in a deactivated state of the laser diode element 10 is directed away from the construction plane 9.

[0067] As will be seen below, the laser diode elements 10 can be arranged in a holding device 12 at predeterminable or predetermined arrangement positions as required. The holding device 12 is arranged within the construction chamber 8. In the Fig. 1 In the embodiment shown, the holding device 12 is attached to a wall of the build chamber 8 and is not movable relative to the build plane 9. The laser diode elements 10 arranged in the holding device 12 are arranged in a defined position, ie, in particular, at a defined distance, relative to the build plane 9.

[0068] Fig. 2 shows a schematic diagram of a device 1 according to a further embodiment.

[0069] A first difference to the Fig. 1 The advantage of the exemplary embodiment shown is that the laser diode elements 10 are arranged one above the other in several planes lying parallel to the construction plane 9. The arrangement of laser diode elements 10 in several planes one above the other results in a particularly compact arrangement of the laser diode elements 10. The arrangement of the laser diode elements 10 in several planes one above the other is selected such that the laser beams 5 that can be generated via the respective laser diode elements 10 can each be directed directly onto the construction plane 9. The laser diode elements 10 arranged in respective planes lying one above the other are arranged with a certain spatial offset relative to one another. A laser beam 5 generated by a laser diode element 10 arranged in the upper plane does not strike a laser diode element 10 arranged in the lower plane, but passes through a free space 14, e.g.in the form of a gap, a bore or another opening, between laser diode elements 10 arranged directly adjacent to one another in the lower plane onto the construction plane 9.

[0070] Another difference to the Fig. 1 The advantage of the exemplary embodiment shown is that the coating device 7 is arranged on the holding device 12. The coating device 7 is arranged on the holding device 12 with one degree of freedom of movement (cf. double arrow 6) relative to the holding device 12. For moving the coating device 7 relative to the holding device 12, a drive or guide device 13, in particular an (electric) motor, is provided, which is coupled to the coating device 7. It is possible to carry out coating processes and exposure processes simultaneously; of course, only parts of the build plane 9 are exposed in which a build material layer has already been formed by the coating device 7.

[0071] Another difference to the Fig. 1 The advantage of the exemplary embodiment shown is that the device 1 comprises an evaluation device 16 for the, in particular optical, evaluation of the surface quality of a layer of building material to be consolidated and / or of a consolidated layer. The evaluation device 16 can be designed as a camera or comprise such a camera. The evaluation device 16 is also arranged on the holding device 12. The evaluation device 16 can also be arranged on the holding device 12 with at least one degree of freedom of movement relative to the holding device 12. For moving the evaluation device 16 relative to the holding device 12, a drive and / or guide device (not shown) coupled to the evaluation device 16, in particular an (electric)motor, can be provided.It is possible to carry out coating processes, exposure processes, and evaluation processes simultaneously; of course, only parts of the build plane 9 are evaluated in which a build material layer has already been formed and exposed by the coating device 7.

[0072] Another difference to the Fig. 1 The advantage of the embodiment shown is that the device 1 comprises a detection device 15 for detecting the temperature of a building material layer to be solidified or of an already solidified layer. The detection device 15 can be designed as a pyrometer or at least comprise such a pyrometer. The temperature values ​​detected by the detection device 15 can form the basis for pre-tempering a building material layer to be solidified or for post-tempering an already solidified building material layer. The detection device 15 is also arranged on the holding device 12. The detection device 15 can also be arranged on the holding device 12 so that it can be moved in at least one degree of freedom relative to the holding device 12.To move the detection device 15 relative to the holding device 12, a drive and / or guide device (not shown), particularly an (electric) motor, coupled to the detection device 15 can be provided. It is possible to perform temperature detection processes and exposure processes simultaneously. The exposure parameters can be adjusted via the control device 11 depending on the detected temperature.

[0073] The laser diode elements 10 are detachably connected to the holding device 12. The detachable connection of the laser diode elements 10 to the holding device 10 is expedient in the event of a defect in a laser diode element 10, since the defective laser diode element 10 can be easily removed from the holding device 12 and replaced. The device 1 can comprise a detection device 17 for detecting a defective laser diode element 10, which, upon detection of a defective laser diode element 10, outputs information relating to a defective laser diode element 10, e.g., acoustically and / or optically. The information can include details about technical specifications, e.g., the type, of the defective laser diode element 10, the exact nature of the defect, the arrangement or position of the defective laser diode element 10 on or in the holding device 12, etc.

[0074] Furthermore, the device 1 can comprise a replacement device 18, which cooperates with the detection device 17, for the partially or fully automated replacement of defective laser diode elements 10. The replacement device 18 comprises a number of gripper elements 19 for gripping laser diode elements 10 during the replacement process. The replacement device 18 can, for example, be designed as a single- or multi-axis robot device or comprise at least one such device.

[0075] The Fig. 3 , 4 each show a schematic diagram of a device 1 according to a further embodiment. The embodiment according to Fig. 3 , 4 does not fall within the scope of the claims. Fig. 3 shows the entire device 1, Fig. 4 shows a section of the device 1, a top view of the construction level 9.

[0076] In the Fig. 3 , 4In the embodiment shown, the laser diode elements 10 are arranged in rows or columns in a plane and cover only a portion of the build plane 9. The laser diode elements 10 are thus located directly opposite a portion, i.e., a partial surface of the total surface, of the build plane 9. The portion of the build plane 9 covered by corresponding laser diode elements 10 can be selectively exposed without the mandatory mechanical movement of the laser diode elements 10 relative to the build plane 9.

[0077] In contrast to the Fig. 1 , 2In the embodiments shown, the holding device 12 is mounted so as to be movable in at least one degree of freedom of movement relative to the construction plane 9. The movement of the holding device 12 is effected via an (electric) motor drive or guide device (not shown) coupled thereto. The movement of the holding device 12 can include translational degrees of freedom of movement along at least one translation axis and / or rotational degrees of freedom of movement about at least one rotation axis (cf. the Fig. 3 , 4 The movement of the holding device 12 can therefore be, for example, a linear, rotary, tilting, or pivoting movement. A tilted or pivoted position of the holding device 12 is Fig. 3 Shown in dash-dotted lines. Combined movements in several different degrees of freedom are possible. The respective degrees of freedom in which the holding device 12 can be movably mounted are indicated by the illustrated axis cross; the holding device 12 can be movably mounted in particular in the translational and / or rotational axes defined by the x-, y-, and z-axes.

[0078] The movement of the holding device 12 can occur simultaneously with the exposure of the build plane 9 by the laser diode elements 10. The holding device 12 can also be moved in different degrees of freedom or in different trajectories relative to the build plane 9 in conjunction with the exposure of the build plane 9 (see Fig. 4 ). In this way, different hardening structures, e.g. weld seams, can be formed in the building material layer to be hardened and residual stresses arising from the process in the object 2 to be manufactured can be reduced, which has a positive effect on the quality of the object 2 to be manufactured.

[0079] In the Fig. 3 , 4 In the embodiment shown with a holding device 12 with laser diode elements 10 arranged thereon or therein in a row-like or column-like arrangement, the holding device 12 can first be moved, for example, along a first movement path defined by a first, for example linear, movement axis over the construction plane 9 and subsequently along a further movement path defined by a further, for example linear, movement axis over the construction plane 9 (cf. the in Fig. 4 holding device 12 shown in dash-dotted lines). The further movement path can, for example, run at an angle, in particular orthogonally, to the first movement path (cf. Fig. 4 ).

[0080] The Fig. 5 , 6 show a schematic diagram of a device 1 according to a further embodiment. Fig. 5 shows a section of the device 1, a top view of the construction level 9, Fig. 6 shows a section of the device 1, a side view of the holding device 12.

[0081] The holding device 12 here comprises a plurality of holding device segments 12a, wherein at least two holding device segments 12a are arranged to be movable in at least one degree of freedom of movement relative to the construction plane 9 and in at least one degree of freedom of movement relative to one another. The movement of the holding device segments 12a can include translational degrees of freedom of movement along at least one translation axis and / or rotational degrees of freedom of movement about at least one rotation axis. Fig. 5 A holding device segment 12a is shown in dash-dotted lines, which can be pivoted counterclockwise relative to another holding device segment 12a. The pivoting movement indicated by the arrow 24 takes place in a plane parallel to the construction plane 9. For example, a coating device 7 can be arranged on the pivotable holding device segment 12a. Figur 6 A pivoting movement of a holding device segment 12a relative to the construction plane 9 is shown in dash-dotted lines. A coating device 7, for example, can be arranged on the pivotable holding device segment 12a.

[0082] The holding device segments 12a can have different functionalities. Typically, a number of laser diode elements 10 are arranged on at least one first holding device segment 12a, e.g., in a row-like and / or column-like arrangement, for illuminating a build material layer to be solidified. A further number of laser diode elements 10 can be arranged on further holding device segments 12a for pre-tempering a build material layer to be solidified and / or for post-tempering an already solidified build material layer. Alternatively or additionally, further functional components of the device 1 can be arranged on further holding device segments 12a. Such further functional components can be, for example, an application orDosing device 25 for applying a specific amount of building material 3 to a building level 9, a coating device 7 for forming a building material layer to be solidified, an evaluation device 16 for, in particular optically, evaluation of the surface quality of a building material layer to be solidified and / or a solidified building material layer, a detection device 15 for detecting the temperature of a building material layer to be solidified or of an already solidified building material layer, etc.

[0083] The Fig. 5 , 6The holding device 12 shown comprises four cross-shaped holding device segments 12a, which are movable individually, in groups, or as a whole relative to the build plane 9 and / or individually or in groups relative to one another. An application or dosing device 25 is arranged on a first holding device segment 12a, a coating device 7 is arranged on a second holding device segment 12a, a number of laser diode elements 10 for illuminating a build material layer to be solidified is arranged on a third holding device segment 12a, and a detection device 15 for detecting the temperature of a solidified build material layer is arranged on a fourth holding device segment 12a.

[0084] Fig. 7 shows a schematic diagram of a device 1 according to a further embodiment. The design according to Fig. 7 does not fall within the scope of the claims. Fig. 7 shows a section of the device 1, a top view of the construction level 9.

[0085] The Fig. 7 The holding device 12 shown comprises six cross-shaped holding device segments 12a, which are movable individually, in groups, or as a whole relative to the construction plane 9 and / or individually or in groups relative to one another. An application orDosing device 25, on a second holding device segment 12a a coating device 7, on a third holding device segment 12a a detection device 15 for detecting the temperature of a building material layer to be solidified, on a fourth holding device segment 12a a number of laser diode elements 10 for illuminating a building material layer to be solidified, on a fifth holding device segment 12a a detection device 15 for detecting the temperature of a solidified building material layer and on a sixth holding device segment 12a an evaluation device 16 for, in particular optical, evaluation of the surface quality of a solidified building material layer.

[0086] In principle, the movement of holding device segments 12a in at least one degree of freedom of movement relative to the construction plane 9 and / or in at least one degree of freedom of movement relative to each other can take place alternatively or in addition to a movement of the entire holding device 12 relative to the construction plane 9. The optionally additional movement of the entire holding device 12 relative to the construction plane 9 is shown in the Fig. 5 , 7 indicated by arrow 26.

[0087] Fig. 8 shows a schematic diagram of a device 1 according to a further embodiment. The design according to Fig. 8 does not fall within the scope of the claims. Fig. 8 shows a section of the device 1 in a perspective view of the device 4 and the construction level 9.

[0088] Based on Fig. 8 The predeterminable or predetermined arrangement positions of laser diode elements 10 on or in the holding device 12 are shown. The arrangement positions of laser diode elements 10 are shown in Fig. 8 distributed in a grid-like manner, so that a matrix-like arrangement of laser diode elements 10 is possible.

[0089] The arrangement positions are typically defined by holding device-side receiving means 20 for receiving at least one laser diode element 10. The number of receiving means 20 corresponds at least to the number of laser diode elements 10. The receiving means can comprise 20 connecting elements (not shown) which interact with corresponding counter-connecting elements (not shown) arranged or formed on the laser diode elements 10 to form a (positionally) stable connection of the laser diode elements 10 to the holding device 12. Through the interaction of corresponding connecting elements and corresponding counter-connecting elements, for example, a positive and / or non-positive connection can be produced; the connecting elements can, for example, be designed as positive and / or non-positive elements, i.e.Plug-in elements, such as plug-in pins or corresponding plug-in receptacles, and / or locking / snap-in elements, such as locking / snap-in projections or corresponding recesses, and / or screw / threaded elements, such as screw or threaded bolts or corresponding screw or threaded receptacles, etc., can be formed. The mating connection elements can be designed as corresponding form-fitting and / or friction-locking elements. Of course, laser diode elements 10 can also be connected to the holding device 12 in a materially bonded manner, e.g., by gluing.

[0090] Based on Fig. 8 It is further apparent that laser diode elements 10 can also be arranged or disposed on or in the holding device 12 in at least one degree of freedom of movement relative to the holding device 12 and thus also relative to the build plane 9. By moving individual, several or all of the laser diode elements 10 relative to the holding device 12, it is possible, for example, to move laser diode elements 10 relative to the building plane 9 with regard to a specific exposure situation. It is also possible to move laser diode elements 10 into a deactivated state in which a respective generateable or generated laser beam 5 is directed away from the build plane 9, i.e., in particular, to tilt or pivot them. The movement of the laser diode elements 10 takes place via an (electro)motor drive or guide device (not shown) coupled to them.The movement of a laser diode element 10 can include translational degrees of freedom along at least one translation axis and / or rotational degrees of freedom about at least one rotation axis. The movement of a laser diode element 10 can thus be, for example, a linear, rotary, tilting, or pivoting movement. Combined movements with several different degrees of freedom are possible. The respective degrees of freedom in which the laser diode elements 10 can be movably mounted are also shown in FIG. Fig. 8 indicated by the illustrated axis cross; the laser diode elements 10 can be movably mounted in particular in the translation and rotation axes defined by the x-, y- and z-axes.

[0091] The movement of the laser diode elements 10 can also take place simultaneously with the exposure of the build plane 9 by the laser diode elements 10. Individual, several or all of the laser diode elements 10 can also be moved in connection with the exposure of the build plane 9 with different degrees of freedom of movement or in different movement paths relative to the build plane 9. In this way, too, different hardening structures, as mentioned, e.g. weld seams, can be formed in the build material layer to be hardened and residual stresses arising due to the process in the object 2 to be produced can be reduced, which has a positive effect on the quality of the object 2 to be produced. Individual, several or all of the laser diode elements 10 can initially, for example, be moved along a first movement path defined by a first, e.g. linear, movement axis across the build plane 9 and subsequently along a further, e.g.linear, movement axis defined further movement path across the construction plane 9. The further movement path can also be angular, in particular orthogonal, to the first movement path.

[0092] The Fig. 9 , 10 each show a schematic diagram of a device 1 according to a further embodiment. The design according to Fig. 9 , 10 does not fall within the scope of the claims. Fig. 9 , 10 each show a perspective view of the device 4 and the construction level 9 as a section of the device 1.

[0093] In connection with the Fig. 9 , 10The exemplary embodiment shown is intended to explain that individual, multiple, or all laser diode elements 10 can be varied in at least one parameter relating to the beam properties of the laser beam 5 that can be generated via it, in particular in their input and / or output power. Individual, multiple, or all laser diode elements 10 can be "dimmable" in a similar way to a dimmable LED. Accordingly, laser beams 5 with different beam properties, i.e., different energy density, intensity, etc., can be generated via the laser diode elements 10 that can be varied in at least one parameter relating to the beam properties, e.g., by varying the input and / or output power. Accordingly, with the simultaneous generation of several laser beams 5, specific total beam energy profiles 21 can be formed. The laser diode elements 10 can be controlled orcan be varied in their output power to produce a total beam energy profile 21 with a specific two- or three-dimensional geometric shape; for which the . Fig. 9 , 10 In the Gaussian total beam energy profile 21 shown as an example, laser diode elements 10 arranged centrally with respect to the total beam energy profile 21 are operated at a higher power than laser diode elements 10 arranged at the edges with respect to the total beam energy profile 21. Fig. 9 , 10 It can be seen that total beam energy profiles 21 can be generated in different orientations relative to the construction plane 9.

[0094] As indicated by arrows 22, the laser diode elements 10 can also be controlled or their output power varied in such a way that a dynamic total beam energy profile 21 is produced that can be moved or moved along the construction plane 9, possibly back and forth, corresponding to a wavefront. For this purpose, the laser diode elements 10 are controlled analogously to an LED display comprising several LEDs for the moving display of alphanumeric symbols. The laser diode elements 10 correspond to the LEDs associated with the LED display.

[0095] In connection with the Fig. 9 , 10In the exemplary embodiment shown, but not limited to this, it should be noted that individual, several or all of the laser diode elements 10 can generally differ in at least one parameter relating to the beam properties of the laser beam 5 that can be generated via them. The formation of certain two- or three-dimensional total beam energy profiles with at least partially identical, similar or different cross-sectional profiles can therefore also be realized by laser diode elements 10 which differ in at least one parameter relating to the beam properties of the laser beam 5 that can be generated via them, e.g. in their input and / or output power.

[0096] Based on the Fig. 9 , 10shown embodiment, it is evident that stationary or moving total beam energy profiles 21 with at least partially identical, similar or different cross-sectional profiles, in general total beam energy profiles 21 of any two- or three-dimensional geometric shape can be realized.

[0097] Fig. 11 shows a schematic diagram of the device 1 according to a further embodiment. The design according to Fig. 11 does not fall within the scope of the claims. Fig. 11 shows a section of the device 1 in a perspective view of the device 4 and the construction level 9.

[0098] Based on Fig. 11 It is evident that by arranging laser diode elements 10 at predeterminable or predetermined arrangement positions of the holding device 12 as required, it is possible for laser diode elements 10 to be arranged or arranged in groups 22 preconfigured in a specific spatial arrangement relative to one another with regard to a possibly cross-sectionally related outer and / or inner contour of an object 2 to be produced, as required, at predeterminable or predetermined arrangement positions of the holding device 12.It is therefore possible in connection with the generative production of an object 2 with a specific outer and / or inner contour to prepare at least one preconfigured group 22 of laser diode elements 10 formed from laser diode elements 10 arranged in a specific spatial arrangement relative to one another, to connect this, as indicated by the arrow 23, to the holding device 12 for carrying out the generative production of the object 2, i.e., for example, to insert it into the holding device 12, and to remove it from the holding device 12 after the production of the object 12 or to exchange it for a subsequent production of another object 2 with a different outer and / or inner contour with another group 22 of laser diode elements 10 preconfigured in a specific spatial arrangement relative to one another with regard to the outer and / or inner contour of the other object 2.

[0099] Respective preconfigured groups 22 of laser diode elements 10 can therefore generally be assigned or associated with an object 2 having a specific geometric shape, i.e., in particular, with a specific outer and / or inner contour. Respective preconfigured groups 22 of laser diode elements 10 can be (temporarily) stored in a warehouse while maintaining the arrangement of the laser diode elements 10 and can be used as often as desired for the additive manufacturing of the objects 2 assigned to them. Of course, it is also possible to reconfigure a preconfigured group 22 of laser diode elements 10 with respect to the geometric shape of another object 2 by rearranging individual, several, or all of the laser diode elements 10 in a manner analogous to a type case ("type case principle").

[0100] Since several objects 2 of geometrically different shapes can be produced in a generative construction process, several differently preconfigured groups 22 of laser diode elements 10 can of course also be present. In the Fig. 11 In the exemplary embodiment shown, differently preconfigured groups 22 of laser diode elements 10 are shown accordingly. An exemplary first group 22 of crescent-shaped laser diode elements 10 is used to produce a crescent-shaped object 2, and an exemplary further group 22 of L-shaped laser diode elements 10 is used to produce an L-shaped object 2.

[0101] Fig. 12 shows a schematic diagram of a device 1 according to a further embodiment. The design according to Fig. 12 does not fall within the scope of the claims.

[0102] In contrast to the Fig. 1 - 11 In the exemplary embodiments shown, the laser diode elements 10 belonging to the device 4 are arranged outside the build chamber 8. The device 4 comprises a number of optical elements 27 arranged within the build chamber 8 directly above the build plane 9. The optical elements 27 are designed to deflect a laser beam 5 generated by at least one laser diode element 10 directly onto the build plane 9. For this purpose, each optical element 27 is optically coupled to at least one laser diode element 10 via a light-guiding element 28, e.g. in the form of a fiber optic cable. An optical element 27 can be designed as a focusing optics 29 comprising one or more optical lens elements for focusing a laser beam 5 onto the build plane 9, or at least comprise one such focusing optics.

[0103] In the Fig. 12 In the embodiment shown, each optical element 27 is optically coupled to (exactly) one laser diode element 10. Alternatively, it is of course conceivable to optically couple at least one optical element 27 to a plurality of laser diode elements 10 or to couple at least one laser diode element 10 to a plurality of optical elements 27 via suitable beam splitting elements (not shown).

[0104] The optical elements 27 are analogous to those in the Fig. 1 - 11 The arrangement of the laser diode elements 10 in a holding device 12 shown in the embodiments shown is also arranged on or in a corresponding holding device 12.

[0105] Since the essential difference between the Fig. 1 - 11 shown embodiments and the in Fig. 12 shown embodiment is that according to Fig. 12 instead of laser diode elements 10, optical elements 27 are arranged within the construction chamber 8, which are optically coupled to laser diode elements 10 arranged outside the construction chamber 8, all statements in connection with the Fig. 1 - 11 shown embodiments; only the laser diode elements 10 arranged within the construction chamber 8 are conceptually arranged according to the Fig. 1 - 11 shown embodiments by means of optical elements 27 optically coupled to laser diode elements 10 arranged outside the construction chamber 8 according to the Fig. 12 to replace the embodiment shown.

[0106] For all exemplary embodiments, different functions, ie in particular pre-tempering of building material layers to be solidified and / or post-tempering of already solidified building material layers, can be realized via laser beams 5 that can be generated via different laser diode elements 10. For example, at least one first laser diode element 10 or a group of first laser diode elements 10 can be configured to generate a laser beam 5 for solidifying building material layers to be solidified, and at least one further laser diode element 10 or a group of further laser diode elements 10 can be configured to generate a laser beam 5 for pre-tempering building material layers to be solidified and / or to generate a laser beam 5 for post-tempering already solidified building material layers.A laser beam 5 generated for solidifying layers of building material typically has a higher energy (density) than a laser beam 5 generated for pre- or post-tempering of layers of building material to be solidified or already solidified.

[0107] Although not shown in the figures, device 1 can comprise a hardware and / or software-implemented simulation device which is configured to simulate at least one object-related object parameter of the object 2 to be produced or produced which is variable during the implementation of a generative construction process.

[0108] Based on or taking into account various information relevant to the respective object parameter to be simulated, such as information about the building material 3 used in the generative construction process, information about various properties, e.g., density, geometry, etc., of the object 2 to be manufactured or manufactured, etc., the simulation device can simulate at least one object-related object parameter that changes during the implementation of a generative construction process with the device 1. For this purpose, the simulation device is equipped with suitable simulation algorithms. The simulation can take place before and / or during the implementation of a generative construction process carried out with the device.

[0109] A corresponding object-related object parameter that changes during the implementation of a generative construction process can be, for example, the heat flow through the object 2 to be manufactured or manufactured during the implementation of a generative construction process and / or the temperature or the temperature distribution of the object 2 to be manufactured or manufactured. Alternatively or additionally, it is conceivable that the object-related object parameter is the mechanical loads, in particular stresses, that may arise in the three-dimensional object 2 to be manufactured or manufactured during the implementation of a generative construction process.

[0110] The device 1 comprises, as mentioned, a control device 11, which is configured for the targeted control of the device, i.e., in particular, for the targeted control of individual, multiple, or all laser diode elements for the respective generation of a laser beam with specific beam properties. The control device 11 generates corresponding control information on the basis of which a targeted control of individual, multiple, or all laser diode elements 9 takes place for the respective generation of a laser beam with specific beam properties. As mentioned, individual, multiple, or all laser diode elements can be variable in at least one parameter relating to the beam properties of the laser beam that can be generated via them, in particular in their input and / or output power. In particular, it is possible for individual, multiple, or all laser diode elements to be "dimmable," similar to a dimmable LED.Accordingly, laser beams with different beam properties, i.e., different energy density, intensity, etc., can be generated via a laser diode element that can be varied in at least one parameter relating to the beam properties, e.g. by varying the input and / or output power.

[0111] The control device 11 can be configured to specifically control individual, multiple, or all laser diode elements 10 to generate a laser beam 5 with specific beam properties based on the object-related object parameter or at least one object-related object parameter simulated by the simulation device. Thus, when appropriately controlled by the control device 11, the device 4 is configured to set or maintain at least one corresponding object-related object parameter to a specific value by appropriately controlling individual, multiple, or all laser diode elements 10 to generate a laser beam 5 with specific beam properties.For example, the device 4 can be configured, when appropriately controlled by the control device 11, to generate and / or maintain a specific heat flow through the object 2 to be produced or produced by appropriately controlling individual, several or all laser diode elements 10 for the respective generation of a laser beam 5 with specific beam properties (as part of the implementation of the generative construction process).

[0112] Using the devices 1 shown in the figures, a method for the generative production of a three-dimensional object 2 can be realized by successively selectively solidifying individual building material layers from solidifiable building material 2 using at least one laser beam 5. The method can be a selective laser melting process (SLM process) or a selective laser sintering process (SLS process).

Claims

1. A method of generatively producing a three-dimensional object (2) by successive layer-by-layer selective solidification of individual layers of solidifiable building material (3), the method comprising: Arranging a plurality of laser diode elements in a plurality of planes one above the other and at a predetermined spatial offset from each other above a construction plane in which the individual layers of construction material are selectively consolidated, the plurality of planes arranged one above the other comprising an upper plane and a lower plane, the arrangement of the laser diode elements in a plurality of planes one above the other being selected such that the laser beams can each be directed directly onto the construction plane, the corresponding planes comprising a corresponding region of the plurality of laser diode elements arranged as a matrix, the predetermined spatial offset being the corresponding region of the plurality of laser diode elements arranged as a matrix, that the laser beams can each be directed directly to the building plane, the respective planes comprising a corresponding region of the plurality of laser diode elements arranged as a matrix, the determined spatial offset forming the corresponding region of the laser diode elements arranged in the upper plane directly above the building plane by alignment with a corresponding space between the corresponding laser diode elements in the lower plane; and Generating, with the corresponding laser diode elements, at least one laser beam directed onto the construction plane in order to produce the at least one three-dimensional object by successive layer-by-layer selective solidification of individual layers of construction material from solidifiable construction material, the specific spatial offset enabling the at least one laser beam emanating from the corresponding region of the laser diode elements arranged in the upper plane to impinge directly onto the construction plane through the corresponding space between the corresponding region of the laser diode elements in the lower plane.

2. The method according to claim 1, further comprising arranging the laser diode elements with respect to an outer or inner contour of the three-dimensional object to be produced.

3. The method according to claim 2, further comprising arranging the laser diode elements in a specific spatial arrangement in preconfigured groups relative to each other at predefined arrangement positions of a holding device.

4. The method according to claim 1, further comprising arranging the laser diode elements on or in a holding device, wherein the laser diode elements are arranged in at least one degree of freedom of movement relative to the holding device.

5. The method according to claim 4, further comprising movably supporting the holding device in at least one degree of freedom of movement relative to the construction plane.

6. The method according to claim 4, further comprising movably arranging at least two holding device segments in at least one degree of freedom of movement relative to the construction plane or relative to each other.

7. The method according to claim 1, further comprising controlling individual, several or all laser diode elements for the respective generation of a laser beam of specific beam properties.

8. The method according to claim 1, further comprising generating, by means of a laser diode element of the laser diode elements, a corresponding laser beam which differs from the other laser beams in at least one beam characteristic.

9. The method according to claim 1, further comprising generating, by means of a first laser diode element of the laser diode elements, a laser beam for solidifying layers of building material to be solidified, and Generating, by means of at least one second laser diode element of the laser diode elements, a laser beam for pre-tempering layers of building material to be solidified and / or for generating a laser beam for post-tempering layers of building material that have already been solidified.

10. The method according to claim 1, further comprising positioning the holding device in a fixed position relative to the construction plane.

11. The method according to claim 1, further comprising forming, by means of a coating device, a layer of building material in the building plane.

12. The method according to claim 1, further comprising detecting, by means of a detection device, the temperature and / or the melting characteristic of a layer of building material to be solidified, a layer in the process of solidifying or a layer of building material which has already been solidified.

13. The method according to claim 1, further comprising evaluating, by means of an evaluation device, the temperature and / or the melting characteristic of a layer of building material to be solidified, a layer which is in the process of solidifying and / or an already solidified layer.

14. The method according to claim 1, further comprising simulating, by means of a simulation device, at least one object-related object parameter changing in the course of performing a generative building process with the device; and Generation, by means of a control device, of a laser beam of specific beam properties on the basis of the or at least one object-related targeted control of individual, several or all laser diode elements simulated by the simulation device for the respective generation of a laser beam of specific beam properties on the basis of the or at least one object-related object parameter simulated by the simulation device.

15. The method according to claim 14, wherein the at least one object-related object parameter is the heat flow through the object to be generatively produced or manufactured and / or the temperature or the temperature distribution of the object to be generatively produced or manufactured, and / or a mechanical load, in particular stress, in the three-dimensional object to be generatively produced or manufactured, which arises in the course of carrying out a generative construction process.