Method and device for generating control data for a device for additive manufacturing of a component

Abstract

The invention relates to a method for generating control data (PS) for a device (1) for additive manufacturing of a component (2) in a manufacturing process, in which method the component (2), in a construction field (8), is constructed in the form of component layers (B) by selective solidification of build-up material (13), preferably comprising a metal-based powder, by irradiating the build-up material (13) with at least one enegry beam (22), the method comprising the steps of: a) obtaining or generating layer information (SI) comprising geometric parameters of component layers and / or information relating to scan vectors of solidification regions (V1, V2, V3, V4) which represent component layers (B) of the component (2); b) selecting or generating a first filling region (F1) for a first solidification region (V1), this filling region (F1) having a filling pattern (FM) of scan vectors (S) parallel to one another with a predefined vector spacing; c) creating a second filling region (F2) having a filling pattern (FM) of scan vectors (S) parallel to one another for a second solidification region (V2) lying on the first solidification region (V1), the scan vectors (S) of the second filling region (F2) being oriented substantially parallel to the scan vectors (S) of the first filling region (F1) and being arranged offset relative thereto; d) generating control data (PS) in such a way that the additive manufacturing device (1) can generate component layers (B) corresponding to the solidification regions (V1, V2, V3, V4) using this control data (PS). The invention further relates to corresponding control data, a method for additive manufacturing, a control data generation device, a control device, and a manufacturing device.

Description

[0001] Method and device for generating control data for a device for the additive manufacturing of a component

[0002] The invention relates to a method and a device ("control data generation device") for generating control data for a device for the additive manufacturing of a component in a manufacturing process in which the component is built up in a build field in the form of component layers by selectively solidifying build material by irradiating the build material with at least one energy beam. The invention further relates to corresponding control data, a method for the additive manufacturing of a component with such control data, a device for additive manufacturing, and a control device for such a device.

[0003] Additive manufacturing processes are becoming increasingly relevant in the production of prototypes and, more recently, in series production. In general, "additive manufacturing processes" refers to manufacturing processes in which a finished product ("component") is built up by depositing material (the "build material"), usually based on digital 3D design data. The build-up is usually, but not necessarily, layered. The term "3D printing" is often used as a synonym for additive manufacturing. The production of models, samples, and prototypes using additive manufacturing processes is often referred to as "rapid prototyping," the production of tools as "rapid tooling," and the flexible production of series components as "rapid manufacturing."As mentioned at the beginning, a key aspect is the selective solidification of the build-up material. In many manufacturing processes, this solidification can be achieved by irradiation with radiant energy, e.g., electromagnetic radiation, in particular light and / or thermal radiation, but possibly also with particle radiation such as electron beams. Examples of processes that use irradiation are "selective laser sintering" or "selective laser melting." In this process, thin layers of a build-up material, usually in powder form, are repeatedly applied one on top of the other. In each layer, the build-up material is selectively solidified by spatially limited irradiation of the areas that will become part of the component after production in a "welding process." The powder grains of the build-up material are partially or completely melted using the energy locally introduced by the radiation at that location.During cooling, these powder grains then solidify into a solid. Typically, the energy beam is guided across the build area along solidification paths, and the remelting or solidification of the material in the respective layer occurs in the form of "weld paths" or "weld beads," so that ultimately, the component contains a multitude of such layers formed from weld paths. In this way, components with very high quality and fracture strength can now be manufactured.

[0004] Hatching is the preferred fill pattern for areas. The energy beam is guided in parallel paths, resulting in a hatching pattern of parallel welding paths or "solidification paths." The hatching can consist of lines of equal length or of different lengths, e.g., in the form of a rectangle as the fill area, but with lines or solidification paths rotated by 45° to the sides of the rectangle. Areas are also often formed in a checkerboard pattern of squares with different rotated fill patterns (which refers to differently rotated hatching).

[0005] To increase strength, the fill patterns of directly superimposed component layers are arranged in a twisted manner. For example, in a checkerboard pattern, superimposed fill patterns are twisted relative to each other. Examination of the components does indeed reveal an increase in strength due to the twisting, but also certain heterogeneities, e.g., in the form of pores within the component structure.

[0006] It is an object of the present invention to provide a method and a device for generating control data for a device for the additive manufacturing of a component, which overcomes the disadvantages of the prior art and in particular allows an improvement in the quality of a component by improving its homogeneity, in particular for reducing pores (e.g. their number and / or size) or a faster production of a component with consistent quality.

[0007] This object is achieved by a method according to patent claim 1, control data according to patent claim 10, a manufacturing method for additive manufacturing according to patent claim 11, a control data generation device according to patent claim 12, a control device according to patent claim 13 and a device according to patent claim 14. A method according to the invention serves to generate control data for a device for the additive manufacturing of a component in a manufacturing process in which the component is built up in a build field in the form of component layers by selective solidification of build material by irradiation of the build material with at least one energy beam.

[0008] It should be noted that the control data does not yet represent a finished component, but rather represents a component because a component consists of layers of hardening paths that have been hardened according to the control data. A component (or its component layers) corresponds to the so-called "hardening regions." This term was chosen because a manufacturing level can contain layers of multiple components, each of which must be hardened individually. Each component layer is represented by a hardening region. If multiple component layers are located on a manufacturing level, they are also represented by multiple hardening regions.

[0009] Each solidification region in turn comprises a number of so-called “fill regions” (usually a plurality of fill regions). This term was chosen because component layers often have a complex pattern of solidification paths. For example, the edge of a component layer is solidified differently than the interior region, whereby the interior region in turn can have several different fill patterns, e.g. with a checkerboard shape. A fill region is then a region of the solidification region with a uniform fill pattern (e.g. a specific hatching). In a checkerboard pattern, for example, the individual boxes represent fill regions. Neighbouring fill regions preferably differ in the type of their fill pattern, e.g. the orientation of the scan vectors (or “scan lines”) in space, their spacing, their length or their shape.However, it can also happen that individual stripes of a hatching are viewed as separate fill patterns, or that two fill areas with an identical fill pattern lie next to each other. It can also happen that one fill area encloses another fill area, such as an outer contour made up of parallel scan vectors (first fill area) enclosing a checkerboard-like inner area (other fill areas).

[0010] A fill area can overlap with an adjacent fill area, whereby the extent of the overlap zones can be adjustable. An overlap is usually positive, but it can also be 0 or negative (distance). Overlap areas are often selected taking into account a dimensional difference between a scan vector in the control data and an actual hardening path in an additive manufacturing process. This is due to the fact that an extension or diameter of the energy beam and a correlating curing region of a hardening path result in the latter having a width extension and can be longer than a corresponding scan vector in the control data. Thus, despite a negative overlap (distance) of scan vectors in production, there can be a positive overlap of hardening paths.Overlapping adjacent fill areas are compatible with the invention, since the invention takes into account the orientation of the fill areas and an overlap is irrelevant as long as the fill areas in question are themselves defined.

[0011] Overview: A fill pattern of (usually parallel) scan vectors represents a fill region, while a hardening region is usually formed from several fill regions. During production, hardening paths are formed along the scan vectors, which are hardened into a component layer according to the fill pattern of the fill regions of a hardening region.

[0012] The method according to the invention comprises the following steps: a) Obtaining or generating layer information comprising geometric parameters of component layers and / or information on scan vectors of solidification regions which represent component layers of the component, b) Selecting or generating a first fill region for a first solidification region, wherein this fill region has a fill pattern of mutually parallel scan vectors with a predetermined vector spacing, c) Creating a second fill region with a fill pattern of mutually parallel scan vectors for a second solidification region lying on the first solidification region, wherein the scan vectors of the second fill region are aligned substantially parallel to the scan vectors of the first fill region and arranged offset therefrom, d) Generating control data such thatthat the additive manufacturing device can produce component layers corresponding to the solidification areas using these control data. As already indicated, in a manufacturing process, build-up material is built up layer by layer in a build field, i.e., successively in several material application levels or material layers. The build-up material is preferably a metal powder or at least a metal-based powder. Such a powder preferably contains more than 50% by weight of metal, in particular more than 60% by weight, 70% by weight, 80% by weight, or even more than 90% by weight of metal. The build-up material can consist of a specific pure metal or can comprise alloy components. However, the invention is not limited to this, but can also be used with other, preferably powdered, build-up materials, such as plastics or ceramics or mixtures of the various materials.In particular, between the application of two material layers, the build-up material is (particularly selectively) solidified by irradiating the build-up material with at least one energy beam generated by an irradiation unit of the production device (this refers to an energetic beam of photons or particles, e.g., a light beam or an electron beam). Not only is the build-up material in the uppermost, freshly applied material layer captured and melted or remelted by the energy beam, but the energy beam typically penetrates a little deeper into the material bed and also reaches the underlying, already remelted material from previously applied material layers.

[0013] The layer information can be prefabricated control data according to the state of the art, particularly with regard to the first component layer, or purely geometric data of the individual component layers, particularly their shape. However, the layer information for the first component layer can also be provided as control data with scan vectors, and further layer information can be provided as purely geometric information for the subsequent component layers. For example, the layer information can be parallel sections of a CAD-generated component or be based on them.

[0014] Since hardening regions contain fill areas with individual fill patterns formed from scan vectors, with which material is to be hardened in the form of the component layers, they represent the component layers of the component. Thus, a hardening region belongs to a component and is not an area that is removed as intended after production. It should be noted that hardening regions can also contain multiple fill areas. Thus, a hardening region can certainly have different fill areas at different locations. The control data can include data on the hardening regions—not necessarily finished control data, but geometric data on the position of the scan vectors of the individual fill areas.

[0015] At least in one solidification region (specified by control data or generated during the process) there is a number, in particular a plurality or even a multiplicity, of fill regions with a (each individual) fill pattern. Each solidification region is therefore formed from a number of fill regions that are to be solidified according to the scan vectors, which means that build-up material is solidified during production and thereby regions with a fill pattern are formed that correspond to the fill patterns of the fill regions. The scan vectors therefore form a predefined fill pattern in each fill region, e.g. a hatching. It is important that at least some of the fill patterns (and thus also some of the fill regions) have parallel scan vectors with a predefined vector spacing, e.g. a hatching, an arrangement of concentric circles or a contour made up of several parallel lines.

[0016] The term "parallel" in the sense of the invention does not necessarily refer to the aligned position of straight lines, but can also refer to curved lines. For example, the lines of concentric circles would also be parallel to each other in the sense of the invention. It should be noted that curved structures are often formed in practice with essentially straight scan vectors. However, even laterally adjacent, evenly spaced, curved scan vectors would be parallel to each other in the sense of the invention. In summary, "parallel" initially simply means the lines, especially straight lines, having the same course.

[0017] The scan vectors have a certain vector spacing from each other. The term "vector spacing" refers to the distance between adjacent, preferably uninterrupted, scan vectors, which is determined in a direction perpendicular to the position of the scan vectors in the same plane (as opposed to a distance to scan vectors in an adjacent strip or box, or in other solidification areas). For solidification paths, the vector spacing would correspond to the distance between the centers of two adjacent solidification paths. It should be noted here that in the case of interrupted hatching, e.g., holes within an otherwise flat hatching, the hole with its surrounding fill pattern is considered a different fill area. The surrounding fill area then has uninterrupted hatching. However, hatching can also be interrupted, at least as long as the scan vectors there remain parallel to each other.

[0018] When selecting the first fill region, it must have a fill pattern of parallel scan vectors. The first solidification region can, for example, correspond to the lowest component layer, but also to any other component layer, but not the topmost one, as otherwise the subsequent process steps cannot be performed.

[0019] However, the first fill area can also be generated from layer information in the form of geometric data. This process is state of the art, well known to those skilled in the art, and is used, for example, when the layer information already contains fill areas or fill patterns.

[0020] It should generally be noted that the process always requires an initial fill pattern to determine and arrange the subsequent, overlying fill patterns. Whether this fill pattern is already present in the layer information or is generated from it is essentially irrelevant.

[0021] Two filling areas are now arranged in (directly) superimposed solidification areas such that the filling patterns are essentially parallel to each other (and thus not rotated relative to each other as in the prior art). The entire filling area could be slightly shifted, or the filling pattern within the filling area could be shifted.

[0022] Like the first fill area, the second fill area also has a fill pattern of parallel scan vectors. The scan vectors of the second fill area are not only aligned essentially parallel to the scan vectors of the first fill area, but are also offset from them. This preferably means a lateral offset, which then results in interlocking of the resulting solidification paths during production. However, it is also possible that adjacent strips of a hatching have a longitudinal offset, so that superimposed strips overlap. The first and second fill areas naturally lie one above the other, although the edges may well be slightly shifted from one another due to the offset. The final generation of control data corresponds to the procedure known in the prior art.Essentially, the scan vectors are translated into control commands that the respective manufacturing device understands, e.g., G-code. The special feature of the generated control data is that component layers can be created according to the specially arranged hardening areas with overlapping fill patterns according to the invention.

[0023] It should be noted that the method is particularly advantageous if the steps of the method for arranging the filling regions are applied to a plurality of solidification regions (for creating component layers), so that two or more solidification regions are created with filling patterns offset according to the invention and then two or more solidification regions are created with filling patterns offset according to the invention which are rotated relative to the underlying ones (i.e., basically steps b) and c) are repeated with each rotated filling pattern.

[0024] The method described above can be used to generate control data according to the invention that serves to control a device for additive manufacturing. As mentioned, this control data is characterized in that scan vectors of directly superimposed solidification regions are arranged substantially parallel and offset from one another. During production, this control data is used to generate component layers that are characterized in that solidification paths of directly superimposed component layers are arranged substantially parallel and offset from one another. This suppresses pores within a component, so that the size and / or number of pores is smaller than in conventional components manufactured solely with twisted fill patterns.

[0025] The control data also preferably includes further design instructions, such as the layered application of build material and, in particular, the lowering of the build platform between component layers. This is implicit in an arrangement of two component layers, since a new component layer can only be applied to an already solidified area by applying new build material. This application usually requires the build platform to be lowered.

[0026] In a manufacturing method according to the invention for the additive manufacturing of a component, the component is built up layer by layer in a build field by selectively solidifying build material, preferably comprising a metal-based powder, by irradiating the build material with at least one energy beam according to the control data according to the invention. To create component layers of the component, the energy beam is moved across the build field according to the control data, i.e., along the scan vectors contained in the control data and thus in the form of the specified fill patterns.

[0027] A control data generation device according to the invention serves to generate control data according to the invention (according to the method according to the invention) for a device for the additive manufacturing of a component in a manufacturing process in which the component is built up in a construction field in the form of component layers by selective solidification of build material, preferably comprising a metal-based powder, by irradiating the build material with at least one energy beam.

[0028] The control data generating device comprises the following components:

[0029] - A data interface designed to receive layer information comprising geometric parameters of component layers and / or information on scan vectors of solidification regions, which represent component layers of the component,

[0030] - a control module designed for i) selecting or generating a first fill area for a first solidification area, wherein this fill area has a fill pattern of mutually parallel scan vectors with a predetermined vector spacing, ii) creating a second fill area with a fill pattern of mutually parallel scan vectors for a second solidification area lying on the first solidification area, wherein the scan vectors of the second fill area are aligned substantially, preferably exactly, parallel to the scan vectors of the first fill area and arranged offset therefrom,

[0031] - a control data generation unit designed to generate control data such that the additive manufacturing device can use this control data to produce component layers corresponding to the solidification regions.

[0032] A control device according to the invention serves a device for the additive manufacturing of a component in a manufacturing process in which the component is built up in a build field in the form of component layers layer by layer by selectively solidifying build material, preferably comprising a metal-based powder, by irradiating the build material with at least one energy beam using an irradiation device. The control device is designed to control the device for the additive manufacturing of the component layers of the component according to control data according to the invention. The control device according to the invention preferably comprises a control data generation device according to the invention.

[0033] A device according to the invention (“manufacturing device”) serves for the additive manufacturing of at least one component in an additive manufacturing process. It comprises at least

[0034] - a feeding device for applying layers of build material to a build area in a process chamber,

[0035] - an irradiation device for selectively solidifying build-up material by irradiation with at least one energy beam, in particular between the application of two material layers, and

[0036] - a control device according to the invention.

[0037] It should be noted at this point that the device according to the invention can also comprise multiple irradiation devices, which are then controlled in a coordinated manner using the control data, as mentioned above. It should also be mentioned again that the energy beam can also consist of multiple superimposed energy beams, or that the energy beam can be either particle radiation or electromagnetic radiation, such as light or, preferably, laser radiation.

[0038] The invention can be implemented in particular in the form of a computer unit, in particular in a control device, with suitable software. This refers in particular to the creation of the control data, since the production of a component takes place using additional components. For this purpose, the computer unit can, for example, have one or more cooperating microprocessors or the like. In particular, it can be implemented in the form of suitable software program components in the computer unit. A largely software-based implementation has the advantage that even computer units already used previously, in particular in control devices of production apparatus, can be easily retrofitted by means of a software or firmware update in order to operate in the manner according to the invention.In this respect, the object is also achieved by a corresponding computer program product with a computer program that can be loaded directly into a memory device of a computer unit, with program sections for executing all steps of the method according to the invention (at least those related to the generation of control data, but possibly also those that serve to transmit the control data for a production process) when the program is executed in the computer unit. Such a computer program product can, in addition to the computer program, optionally comprise additional components such as documentation and / or additional components, including hardware components such as hardware keys (dongles, etc.) for using the software.A computer-readable medium, for example a memory stick, a hard disk or another portable or permanently installed data storage device, on which the program sections of the computer program that can be read and executed by a computer unit are stored, can be used for transport to the computer unit and / or for storage on or in the computer unit.

[0039] Further, particularly advantageous embodiments and developments of the invention emerge from the dependent claims and the following description, wherein the independent claims of one claim category can also be developed analogously to the dependent claims and embodiments of another claim category and, in particular, individual features of different embodiments or variants can be combined to form new embodiments or variants.

[0040] A preferred method comprises the following step after step c) and before step d) (i.e. after the parallel and offset arrangement of scan vectors and before the generation of control data):

[0041] - Creating a third fill region from mutually parallel scan vectors for a third solidification region, wherein the third fill region lies above the first fill region (in particular directly above the second fill region) and at least partially covers it, and wherein the fill pattern of the third fill region is rotated relative to the fill pattern of the first fill region (and thus also relative to the fill pattern of the second fill region), in particular by a rotation angle of more than 10°, preferably wherein the fill pattern of the third fill region is (geometrically) identical to the fill pattern of the first fill region except for the rotation of scan vectors. The global extent of the fill regions could well be different, since the geometry of a component can change from layer to layer. It should be noted that the third fill region does not necessarily have to lie on the second fill region, but that, if necessary,Additional fill regions may be located between the second fill region and the third fill region, which have a parallel and offset arrangement of scan vectors relative to the first fill region. However, the third fill region must lie above the first fill region, meaning that its projection along the surface normal of the solidification region lies substantially (at least 80%) on the first surface region.

[0042] The preceding step is particularly preferably followed by a step corresponding to step c):

[0043] - Creating a fourth filling area from mutually parallel scan vectors for a fourth solidification area lying on the third solidification area, wherein the scan vectors of the fourth filling area are aligned substantially parallel to the scan vectors of the third filling area and arranged offset therefrom.

[0044] It is particularly preferred that after a rotation, the number of layers in which offset filling patterns are provided according to the invention corresponds to the number of underlying layers, i.e., for example, two, three or more solidification regions directly above one another with offset filling patterns (with parallel scan vectors) are always provided, then the fill patterns are rotated and again two, three or more solidification regions directly above one another with offset filling patterns (with mutually parallel scan vectors) are provided.

[0045] It should be noted here that the designations “first”, “second”, “third” and “fourth” serve only to improve differentiation and do not exclude the possibility that further component layers with filling patterns offset according to the invention could be located between the solidification regions two and three.

[0046] According to a preferred method, the scan vectors of the second filling region are shifted in a plane of the second solidification region relative to the scan vectors of the first filling region in a transverse direction relative to a longitudinal extent of the scan vectors of the first filling region. This means that, viewed from above, they lie in spaces between two underlying scan vectors. The corresponding vector spacings of the filling patterns of the filling regions are preferably identical in each case. It is preferred that a shift distance in the transverse direction is smaller than the vector spacing between two scan vectors. This shift distance is preferably in the range between 90% and 10% of the vector spacing and particularly preferably in the range between 45% and 55% of the vector spacing. It is particularly preferred that the shift distance is greater than 10% of the vector spacing, in particular greater than 20%, in particular greater than 30%, in particular greater than 40%.On the other hand, it is particularly preferred that the displacement distance is less than 90% of the vector distance, in particular less than 80%, in particular less than 70%, in particular less than 60%. For example, the scan vectors of the offset fill pattern in question lie exactly in the middle (50% of the vector distance) between scan vectors of the immediately underlying fill pattern. If fill patterns lie parallel to one another in exactly three directly superimposed solidification regions, it may also be preferred that the scan vectors are each shifted by 1 / 3 of the vector distance from one another. In absolute terms, an offset is preferably less than 0.2 mm, particularly preferably less than 0.1 mm, at least with conventional scan vectors.

[0047] As stated above, at least some of the fill patterns have mutually parallel scan vectors with a predetermined vector spacing. In this regard, a preferred fill pattern is formed from a hatching of a plurality of mutually parallel scan vectors. Alternatively, a preferred fill pattern is formed from a contour of mutually parallel scan vectors, whereby this means an edge region of the solidification region that is formed from two or more scan vectors. Alternatively, a preferred fill pattern is formed from a circular or spiral arrangement of a number of scan vectors. Basically, it is only important that scan vectors run parallel to one another so that an offset can be achieved in fill regions that lie directly above one another.

[0048] It is preferred that, in superimposed solidification regions, fill regions essentially overlap one another over their entire surface. Preferably, fill regions with an identical shape and size essentially overlap one another over their entire surface. The term “essentially” means that at least 80%, in particular at least 90%, of the areas overlap one another. It should be noted here that, preferably, the fill patterns within the fill regions are offset from one another in order to achieve the required offset of the scan vectors. Alternatively or additionally (possibly at a different location in the solidification regions), fill regions are preferably arranged offset from one another, preferably with fill regions with a similar or identical fill pattern being offset from one another along the scan vectors by a predetermined offset distance.

[0049] Alternatively or additionally (possibly at a different location within the solidification areas), fill areas are arranged rotated relative to each other without their fill patterns being rotated. For example, for rectangular fill areas, this means that the sides of the fill areas are rotated relative to each other, but the scan vectors of these overlapping fill areas are not rotated relative to each other and are still parallel (and offset) to each other.

[0050] Alternatively or additionally (possibly at another location in the solidification areas), filling patterns of overlapping filling areas differ from each other with respect to an offset along and / or across their scan vectors, and / or with respect to a rotation of their scan vectors.

[0051] It is preferred that a displacement distance in the longitudinal direction is less than a strip width (standard length or maximum length of the relevant scan vectors) of a fill area in the form of a hatched strip. The displacement distance is preferably in the range between 90% and 10% of the strip width, and particularly preferably in the range between 45% and 55% of the strip width. It is particularly preferred that the displacement distance is greater than 10% of the strip width, in particular greater than 20%, in particular greater than 30%, in particular greater than 40%. On the other hand, it is particularly preferred that the displacement distance is less than 90% of the strip width, in particular less than 80%, in particular less than 70%, in particular less than 60%.In contrast to the transverse offset described in more detail above, a longitudinal offset is described here, which is possible as an alternative or in addition to the transverse offset and improves the stability as well as the quality (with regard to the homogeneity of the microstructure) of a component.

[0052] Particularly preferably, a displacement occurs in the transverse direction and in the longitudinal direction, wherein the displacement distance is in particular less than a diagonal extension of the first filling region. The displacement distance is preferably in the range between 90% and 10% of the diagonal extension, and particularly preferably in the range between 45% and 55% of the diagonal extension. It is particularly preferred that the displacement distance is greater than 10% of the diagonal extension, in particular greater than 20%, in particular greater than 30%, in particular greater than 40%. On the other hand, it is particularly preferred that the displacement distance is less than 90% of the diagonal extension, in particular less than 80%, in particular less than 70%, in particular less than 60%.

[0053] According to a preferred method, within a filling region and / or between two directly superimposed filling regions, the values ​​of a number of parameters of the energy beam for solidifying a building material are changed during solidification along the scan vectors. These parameters are, in particular, a speed (at which the energy beam is guided over the building material along a scan vector), a power, a pulse pattern, and / or an intensity distribution. In particular, the respective values ​​of the number of parameters change between the first filling region and the second filling region and / or the third filling region and the fourth filling region. Thus, here (in particular parallel and offset) scan vectors of directly superimposed filling regions are provided with different energy beam parameters for the control data.

[0054] According to a preferred method, the control data is generated such that the energy beam is adjusted such that it solidifies a region deeper than the thickness of the respective last component layer during solidification along the scan vectors. This solidification depth is preferably at least twice, more preferably at least three times, and particularly preferably at least four times the thickness of the respective last component layer. Particularly preferably, a solidification has a depth extension greater than 0.05 mm, in particular greater than 100 μm and / or less than 300 μm.

[0055] Solidification preferably takes place in the form of a deep penetration welding process. Deep penetration welding is defined as a process in which a vapor capillary forms, also known as a "keyhole." The incident energy beam creates a pool of molten material. When the surface of the material reaches its boiling point, the resulting vapor bubble pushes the melt sideways and downwards, thus creating the vapor capillary. The diameter of this keyhole is smaller than that of the energy beam or laser beam. The vapor capillary also forms depending on the speed of movement of the energy beam; for a laser, this typically starts at an intensity of 2 MW / cm2 at 1 m / min. The deeper the keyhole becomes, the greater the forces that tend to collapse it, and the more power of the energy beam has already been absorbed, so that equilibrium is finally reached at a certain depth dependent on certain parameters.Due to the formation of vapor capillaries on the surface of the build-up material, the beam penetrates deeper beneath the surface of the layer to be consolidated. This can result in multiple reflections of the beam, which improves radiation absorption. A deep penetration welding process is preferred for forming consolidating tracks. The speed should be selected to ensure a stable weld seam and prevent humping.

[0056] As already mentioned above, a particular advantage of the invention is the reduction of porosity in a component. The number and size of pores should be small to ensure high component quality. From the size G and / or the number A of pores, a specific comparison measure V can also be derived, e.g., with the weighting variables a, b, c, d according to the formula V = aR+bG+cGR+d. The values ​​for the size G and / or the number A of pores can be specified in the form of parameter values, e.g., as a vector or value field (G, A). It should be noted that the "comparison measure" does not specify a ratio of a comparison, but represents a measure for a comparison. Using their respective comparison measures, two components can then be compared with each other, and a "quality measure" can be determined as a comparison value, e.g., in the form of a difference or a quotient of their comparison measures. It can, for example,A standard reference measurement is used, and this is compared with a reference measurement of a test specimen. The deviation of the reference measurement from the standard reference measurement (the quality measurement) then determines the quality of the test specimen.

[0057] The layer information initially provided to the method can contain predefined vector spacings of the scan vectors and, as a rule, predefined scanning speeds. Prior knowledge of the quality improvement of the invention could be incorporated into this layer information in advance, thereby achieving faster production. However, the method could also modify predefined vector spacings of the scan vectors or scanning speeds in provided layer information or generate new (possibly modified) layer information in order to achieve an increase in process efficiency while maintaining consistent quality (compared to production without application of the method according to the invention). According to a preferred method, a quality measure is determined from a comparison of pores of test specimens. This method comprises the following steps:

[0058] - producing a target test body with control data which has been created using a method according to one of the preceding claims,

[0059] - producing a reference test body with control data at least without a staggered arrangement of scan vectors according to step c) of the (inventive) method,

[0060] - Determining parameter values ​​for parameters of pores of the target test body and the reference test body using the same measuring method, wherein the parameter values ​​of the pores include in particular their size and / or their number,

[0061] - Creating a comparison measure of the determined parameter values ​​of the target test body and the reference test body,

[0062] - Optionally: producing test specimens with control data using a method according to one of the preceding claims, wherein the layer information is modified or generated such that a vector distance between scan vectors of the filling areas and / or a scanning speed for these scan vectors is increased and

[0063] - Optional: Investigating changes in the comparison measure by comparing the test specimens with the reference test specimen in relation to the layer information, e.g. the modifications of the layer information and creating a comparison measure, depending on the layer information, e.g. the modifications of the layer information,

[0064] - Creating the quality measure based on a number of created comparison measures.

[0065] As mentioned, the quality measure is a measure that indicates a comparison of the quality of a test specimen. The reference test specimen represents the reference for the quality (and provides the aforementioned "standard comparison measure"). The quality is derived from the comparison measures, i.e., the pores. The larger and more frequent the pores, the poorer the quality. Essentially, the quality measure can be derived directly from a comparison measure or from a comparison of pore values, e.g., according to the above-mentioned formula P = aR+bG+cGR+d with the comparison measure of the reference test specimen.

[0066] The target test specimen is manufactured with offset fill areas according to the invention, and the reference test specimen with successively rotated fill areas. The (optional) experimental test specimens are manufactured according to the target test specimens, but with varied scan speeds and vector spacing. In principle, the scan speed can simply be successively increased or the vector spacing can be successively increased for different experimental test specimens.

[0067] The comparison measure can simply be a ratio or difference between the parameter values ​​of the target test specimen (or reference test specimens) and the reference test specimen. It can also contain composite values ​​from GA.

[0068] Essentially, a single target test specimen is sufficient, at least if sufficient theoretical knowledge is available to derive a quality measure from the measurements on this test specimen. However, more precise results can be achieved using experimental test specimens, as these were manufactured using different production parameters. Essentially, it is now sufficient to determine which production parameters (scan speed or vector spacing) were used to produce a test specimen that exhibits the quality of the reference test specimen (or even better).

[0069] Preferably, based on the quality measure, the obtained or generated layer information is modified by increasing the vector spacing between scan vectors of the fill areas and / or by increasing the scanning speed for these scanning vectors, and the steps of the method are carried out based on the modified or generated layer information. The scanning speed is preferably increased or the vector spacing is increased. Although this reduces the quality of a manufactured component, its production can be accelerated at the expense of quality. If the quality of the component is to be the same as that of a conventionally manufactured component, its production can be accelerated. However, production can also be accelerated only slightly, and a component of better quality can be produced. The desired quality is predetermined by the quality measure.

[0070] The quality measure includes, in particular, information about a relationship to modifications of the layer information, i.e. information about the extent to which the vector spacing and / or the scanning speed have been changed.

[0071] The invention will be explained in more detail below with reference to the accompanying figures using exemplary embodiments. In the various figures, identical components are provided with identical reference numerals. They show: Figure 1 is a schematic, partially sectioned view of an exemplary embodiment of an apparatus for additive manufacturing.

[0072] Figure 2 shows a design of filling areas of different solidification areas with filling patterns according to the state of the art,

[0073] Figure 3 shows a design of filling areas of different solidification areas with filling patterns according to an embodiment of the invention,

[0074] Figure 4 shows an example of a solidification area with different filling areas,

[0075] Figure 5 is a block diagram of a possible process sequence of an embodiment of a method according to the invention,

[0076] Figure 6 is a block diagram of a possible process sequence of an embodiment of a method according to the invention for increasing the process speed.

[0077] The following exemplary embodiments are described with reference to a device 1 for the additive manufacturing of components in the form of a selective laser sintering or laser melting device. It should be explicitly noted that the invention is not limited to selective laser sintering or laser melting devices. The device will therefore be referred to below—without limiting its generality—as "manufacturing device" 1.

[0078] Such a manufacturing device 1 is shown schematically in Figure 1. The device has a process chamber 3 or a process space 3 with a chamber wall 4, in which the manufacturing process essentially takes place. Located within the process chamber 3 is an upwardly open container 5 with a container wall 6. The upper opening of the container 5 forms the current working plane 7. The area of ​​this working plane 7 lying within the opening of the container 5 can be used to build the object 2 and is therefore referred to as the construction field 8.

[0079] The container 5 has a base plate 11 which is movable in a vertical direction V and is arranged on a carrier 10. This base plate 11 closes off the container 5 at the bottom and thus forms its base. The base plate 11 can be formed integrally with the carrier 10, but it can also be a plate formed separately from the carrier 10 and fastened to the carrier 10 or simply mounted thereon. Depending on the type of specific construction material, for example the powder used, and the manufacturing process, a construction platform 12 can be attached to the base plate 11 as a construction base on which the object 2 is built. In principle, however, the object 2 can also be built on the base plate 11 itself, which then forms the construction base.

[0080] The basic construction of object 2 occurs by first applying a layer of build material 13 to the build platform 12. Then, as explained later, the build material 13 is selectively solidified using a laser beam 22 as an energy beam at the points that are to form parts of the object 2 to be manufactured. Then, with the aid of the carrier 10, the base plate 11, thus the build platform 12, is lowered, and a new layer of build material 13 is applied and selectively solidified, etc. In Figure 1, the object 2 constructed in the container on the build platform 12 is shown below the work plane 7 in an intermediate state. It already has several solidified layers, surrounded by unsolidified build material 13.Various materials can be used as the building material 13, preferably powder, in particular metal powder, plastic powder, ceramic powder, sand, filled or mixed powders or also pasty materials and optionally a mixture of several materials.

[0081] Fresh build material 15 is located in a storage container 14 of the production device 1. With the aid of a coater 16 movable in a horizontal direction H, the build material can be applied in the form of a thin layer in the working plane 7 or within the build area 8.

[0082] Optionally, an additional radiant heater 17 is located in the process chamber 3. This can be used to heat the applied build material 13, so that the irradiation device used for selective solidification does not have to introduce too much energy. This means, for example, that with the help of the radiant heater 17, a certain amount of basic energy can be introduced into the build material 13, which is naturally still below the energy required for the build material 13 to melt or sinter. An infrared radiator or VCSEL radiator, for example, can be used as the radiant heater 17.

[0083] For selective solidification, the production device 1 has an irradiation device 20, or more specifically, an exposure device 20 with a laser 21. This laser 21 generates a laser beam 22, which is deflected by a deflection device 23 in order to traverse the scan vectors S provided according to the exposure strategy in the respective layer to be selectively solidified and to selectively introduce the energy. Furthermore, this laser beam 22 is appropriately focused onto the working plane 7 by a focusing device 24. The irradiation device 20 is preferably located outside the process chamber 3, and the laser beam 22 is guided into the process chamber 3 via a coupling window 25 mounted on the top side of the process chamber 3 in the chamber wall 4.

[0084] The irradiation device 20 can, for example, comprise not just one but several lasers. These can preferably be gas or solid-state lasers or any other type of laser, such as laser diodes, in particular VCSELs (Vertical Cavity Surface Emitting Lasers) or VECSELs (Vertical External Cavity Surface Emitting Lasers), or a row of these lasers. Very particularly preferably, one or more unpolarized single-mode lasers, e.g., a 3 kW fiber laser with a wavelength of 1070 nm, can be used within the scope of the invention.

[0085] To control the units of the manufacturing device 1, a control device 30 comprising a control unit 29 is used, which controls the components of the irradiation device 20, namely here the laser 21, the deflection device 23 and the focusing device 24, and for this purpose transmits corresponding control data PS to them.

[0086] The control unit 29 also controls the radiant heater 17 by means of suitable heating control data HS, the coater 16 by means of coating control data ST and the movement of the carrier 10 by means of carrier control data TS and thus controls the layer thickness.

[0087] The control device 30 is coupled, here, for example, via a bus 60 or another data connection, to a terminal 40 with a display or the like. Via this terminal 40, an operator can control the control device 30 and thus the entire laser sintering device 1, for example, by transmitting process control data PS.

[0088] In order to optimize the production process, the control data PS are generated or modified in the manner according to the invention by means of a control data generation device 34 such that the device 1 is controlled at least temporarily in a mode according to the invention. The control data generation device 34 here comprises a data interface 35 for receiving layer information S1 for a component 2. This layer information S1 already comprises, for example, layer structures of the component (the solidification regions V1, V2, V3, V4, see the following figures). Alternatively, the control data generation device 34 comprises a cutting unit 35 designed to generate this layer information S1. Surfaces of the layer structures are to be solidified with a predetermined filling pattern F (see also the following figures for the functions of the components).

[0089] In this example, the layer information S1 contains data about solidification regions V1, V2, V3, V4, which represent component layers B of the component 2, wherein the solidification regions V1, V2, V3, V4 are formed from a number of fill regions F1, F2, F3, F4. Furthermore, the layer information S1 includes data about scan vectors S, according to which the fill regions F1, F2, F3, F4 are to be solidified. The scan vectors S form a predetermined fill pattern FM in each fill region F1, F2, F3, F4, wherein at least some of the fill patterns FM have parallel scan vectors S with a predetermined vector spacing. It should be noted here that the layer information S1 does not yet represent finished component layers B, since the latter are only created using the layer information S1.The solidification regions V1, V2, V3, V4 are therefore not solidified regions, but generally represent a plurality of filling regions F1, F2, F3, F4, wherein each filling region in turn generally comprises a plurality of scan vectors S arranged in the form of a filling pattern (often in the form of hatching). If an energy beam 22 is guided along these scan vectors S over a layer of build material 13, the build material 13 is solidified there in the form of solidification paths with the corresponding filling patterns F1, F2, F3, F4. Therefore, the solidification regions V1, V2, V3, V4 represent the component layers B, the scan vectors S the solidification paths of the component layers B and the filling regions F1, F2, F3, F4 individual regions of the component layers B with a uniform filling pattern FM.

[0090] In addition to the data interface 35, the control data generation device 34 comprises a control module 36. This control module 36 is designed to select a first fill region F1 for a first solidification region V1 and then to create a second fill region F2 for a second solidification region V2 lying on the first solidification region V1. Each fill region F1, F2 has a fill pattern FM made up of parallel scan vectors S. However, the control module can also be designed to generate the first fill region F1 (and also further fill regions) of the first solidification region V1, in particular in the case that the layer information S1 exclusively comprises geometric data relating to the component 2.

[0091] It is important that the scan vectors S of the second filling region F2 are aligned essentially (preferably exactly) parallel to the scan vectors S of the first filling region F1 and arranged offset to these. This means that later the solidification paths in the resulting component layers B do not run rotated to one another, but parallel and offset to one another. Only when at least two solidification regions V1, V2 have such "untwisted" filling regions F1, F2 can a rotation of filling regions F3, F4 or their filling patterns FM take place, whereby here too it is preferable to provide at least two solidification regions V3, V4 with "untwisted" filling regions F3, F4 to one another after one rotation and before the next rotation, which can continue over the entire component height.

[0092] Furthermore, the control data generation device 34 comprises a control data generation unit 37, which is designed to generate control data PS in such a way that the device 1 for additive manufacturing can produce component layers B corresponding to the solidification regions V1, V2, V3, V4 using this control data PS.

[0093] In a particularly preferred variant, the control data generation device 34 is implemented on an external computer unit, for example, the terminal 40, and already supplies process control data PS with correspondingly suitable control data PS in advance, with which the device 1 is controlled such that the intended mode is achieved in the desired areas of the component. In this case, the internal control data generation device 34 present in the control device 30 could also be dispensed with.

[0094] It should also be noted again at this point that the present invention is not limited to such a manufacturing device 1. It can be applied to other methods for the generative or additive production of a three-dimensional object by layer-by-layer application and selective solidification of a building material, wherein an energy beam is emitted onto the building material to be solidified. Accordingly, the irradiation device can be not only a laser, as described here, but any device could be used with which energy can be selectively applied to or into the building material as wave or particle radiation. For example, another light source, an electron beam, etc., could be used instead of a laser.

[0095] Even though only a single object 2 or component 2 is shown in Figure 1, it is possible and generally common practice to produce multiple objects in parallel in the process chamber 3 or container 5. For this purpose, the build material is scanned layer by layer by the energy beam 22 at locations that correspond to the cross-sections of the objects in the respective layer.

[0096] Figures 2 and 3 show a design of fill areas F1, F2, F3, F4 of different hardening areas V1, V2, V3, V4 with fill patterns FM. The hardening areas V1, V2, V3, V4 lie directly above one another and would result in four consecutive component layers B during production. Each fill pattern FM is a hatching of scan vectors S, each with the same vector spacing. The scan vectors S are not continuous, but form stripes that abut each other at strip boundaries G (indicated by dotted lines) and slightly overlap.

[0097] Figure 2 shows a design according to the prior art. From left to right, a first fill area F1 in a first consolidation area V1 is covered by a second fill area F2 in a second consolidation area V2 with a rotated fill pattern FM. This is followed by a third and fourth consolidation area V3, V3 with further rotated fill patterns FM in the corresponding fill areas F3, F4. The rotation in this example is 90° and can, in practice, essentially assume any desired angle.

[0098] Figure 3 shows a design according to an embodiment of the invention. In contrast to the prior art, here a rotation does not occur between each solidification region V1, V2, V3, V4, but only after every second one. From left to right, a first fill region F1 in a first solidification region V1 is covered by a second fill region F2 in a second solidification region V2 with a non-rotated fill pattern FM. Rather, the fill patterns FM overlap one another in an offset manner, with the underlying scan vectors S of the first fill region F1 in the second fill region F2 being indicated by dash-dotted lines. In this example, the offset occurs both transversely to the longitudinal direction of the scan vectors S and in the longitudinal direction across strip boundaries G. After a rotation of the fill pattern in the third solidification region V4, the fill pattern FM is again offset in the fourth solidification region V4.

[0099] It should be noted that here the fill patterns FM have been rotated within fill areas F1, F2, F3, and F4. It is also possible to rotate fill areas F1, F2, F3, and F4 along with their fill pattern FM.

[0100] Figure 4 shows an example of a solidification region V1 with different fill regions F1, F2, F3, F4. Three inner fill regions F2, F3, F4, arranged in a checkerboard pattern with different fill patterns FM, are surrounded by a fill region F1 that represents the contour or edge of the solidification region V1. While the fill patterns FM in the inner region are hatchings, the scan vectors S of the fill pattern FM of the outer fill region F1 each run parallel to each other around the inner region.

[0101] Figure 5 shows a block diagram of a possible method sequence of an embodiment of a method according to the invention for generating control data PS for a device 1 for the additive manufacturing of a component 2 in a manufacturing process in which the component 2 is built up in a construction field 8 in the form of component layers B by selective solidification of building material 13, e.g. comprising a metal-based powder, by irradiating the building material 13 with at least one energy beam 22.

[0102] In step I, layer information S1 is generated or obtained about solidification regions V1, V2, V3, V4. The solidification regions V1, V2, V3, V4 represent component layers B of the component 2 and are each formed from a plurality of fill regions F1, F2, F3, F4. The layer information S1 comprises data on scan vectors S according to which the fill regions F1, F2, F3, F4 are to be solidified, wherein the scan vectors S form a predetermined fill pattern FM in each fill region F1, F2, F3, F4 and at least some of the fill patterns FM have mutually parallel scan vectors S with a predetermined vector spacing (see, for example, Figure 2).

[0103] The layer information may well be control data according to the prior art, which is modified by the method into control data PS according to the invention. However, it may also comprise merely geometric data of the component 2 or its component layers. In step II, a first fill region F1 with a fill pattern FM made up of parallel scan vectors S is selected or generated for a first solidification region V1. The selection or generation can successively extend to further fill regions F2, F3, F4 and theoretically affect all fill regions F1, F2, F3, F4 of the solidification region V1, wherein the subsequent steps then also take place for the fill regions F1, F2, F3, F4 of the overlying solidification regions V2, V3, V4, either separately from one another or in parallel to one another.Thus, the following explanations can also extend to other fill areas F2, F3, and F4, but for clarity, we will continue here using only one fill area F2 as an example. This step could involve selecting the left fill area F1 in Figure 3.

[0104] In step III, a second filling region F2 is created with a filling pattern FM consisting of parallel scan vectors S for a second solidification region V2 lying on the first solidification region V1, wherein the scan vectors S of the second filling region F2 are aligned substantially parallel to the scan vectors S of the first filling region F1 and arranged offset therefrom. The arrows in the corresponding box indicate that the offset can be transverse and / or longitudinal to the longitudinal direction of the scan vectors S. The offset can, for example, be exactly half a vector distance of scan vectors S. This step could result in the second filling region F2 from the left in Figure 3.

[0105] In step IV, a third fill area F3 is created from parallel scan vectors S for a third solidification area V3. This third fill area F3 lies above and overlaps the first fill area F1. The fill pattern FM of the third fill area F3 is rotated relative to the fill pattern FM of the first fill area V3. This step could result in the third fill area F2 from the left in Figure 3.

[0106] The dashed arrow pointing back to step III indicates that this procedure (parallel arrangement, then rotation) can be repeated as desired.

[0107] In step V, control data PS are then generated in such a way that the device 1 for additive manufacturing can produce component layers B corresponding to the solidification areas V1, V2, V3, V4 using these control data PS.

[0108] This process provides control data PS, which can be used to create components 2 with very low porosity and thus very high component quality. However, it may be desirable not to increase the component quality, as it is already sufficient. In this case, the process can be modified so that the scanning speed and / or the vector spacing of the scan vectors S are increased during the generation of the control data PS, thus reducing the production time. Although this degrades the quality of the components, the higher quality achieved by the process keeps it within the tolerable range or the desired range.

[0109] Figure 6 shows a block diagram of a possible process sequence of an embodiment of a method according to the invention for increasing process speed. In this method, a quality measure is first determined from a comparison of pores in test specimens, and then the control data PS is modified accordingly.

[0110] In step 1a, a target test body TZ with control data PS from a method according to the invention and a reference test body TR with conventional control data PS (without a staggered arrangement of scan vectors S according to step III of the method) are manufactured.

[0111] In step lla, parameter values ​​for parameters of pores P of the target test body TZ and the reference test body TR are determined using the same measuring method, wherein the parameter values ​​of the pores P include in particular their size and / or their number.

[0112] In step IIIa, a comparison measure VM of the determined parameter values ​​of the target test body TZ and the reference test body TR is created, e.g. a ratio of the sizes or the number of pores P.

[0113] Dashed arrows below indicate optional steps in which test specimens TV were produced with control data PS according to the invention, in which the layer information S1 was modified such that a vector distance between scan vectors S of the fill areas F1, F2, F3, F4 and / or a scan speed for these scan vectors S is increased. This example assumes a modification of layer information. The layer information can also be generated, with the following comparisons with the original and the generated layer information being carried out analogously. Based on these test specimens TV, the comparison dimension VM is now again determined in comparison with the reference test specimen TR, but this time in relation to the modifications to the layer information S1.

[0114] In step IVa, the quality measure Q is then determined based on at least one comparison measure VM. This can be the comparison measure from step IIIa directly or comparison measures from the optional steps.

[0115] In step Va, control data PS are then generated based on the quality measure Q, so that the device 1 for additive manufacturing can produce component layers B with this control data PS. In this example, the scanning speed and / or the vector distance between two scan vectors S are dimensioned such that a predetermined component quality is not undercut, whereby the quality measure Q indicates whether the expected component quality is still within a tolerable range or not.

[0116] In a simple case, it is easy to estimate in the aforementioned optional steps using the comparison measure VM whether the quality of a test specimen TV corresponds to the quality of the reference test specimen TR and to select exactly the parameters for the control data PS that were available during the production of this test specimen TV.

[0117] Finally, it should be noted once again that the devices described in detail above are merely exemplary embodiments that can be modified in a variety of ways by those skilled in the art without departing from the scope of the invention. For example, solidification could be carried out using other energy beams instead of laser light. Furthermore, the use of the indefinite articles "a" or "an" does not exclude the possibility that the respective features may be present in multiple locations. Likewise, the term "unit" does not exclude the possibility that it consists of several interacting subcomponents, which may also be spatially distributed. The expression "a number" is to be understood as "at least one." List of Reference Symbols

[0118] 1 device for additive manufacturing / manufacturing device

[0119] 2 Component / Object

[0120] 3 Process room / process chamber

[0121] 4 chamber wall

[0122] 5 containers

[0123] 6 Container wall

[0124] 7 Working level

[0125] 8 Construction site

[0126] 10 carriers

[0127] 11 Base plate

[0128] 12 Construction platform

[0129] 13 Construction material (in container 5)

[0130] 14 storage containers

[0131] 15 assembly material (in storage container 14)

[0132] 16 coaters

[0133] 17 Radiant heating

[0134] 20 Irradiation device / exposure device

[0135] 21 lasers

[0136] 22 Laser beam / energy beam

[0137] 23 Deflection device / scanner

[0138] 24 Focusing device

[0139] 25 coupling windows

[0140] 29 Control unit

[0141] 30 Control device

[0142] 31 Irradiation control interface

[0143] 34 Control data generating device

[0144] 35 Data interface

[0145] 36 Control module

[0146] 37 Control data generation unit

[0147] 40 Terminal

[0148] 60 buses

[0149] B component layer

[0150] FM fill pattern

[0151] F1, F2, F3, F4 Fill area G Strip boundaries

[0152] H horizontal direction

[0153] HS heating control data

[0154] P Pore PS Process control data / control data

[0155] Q quality measure

[0156] S scan vector / hatch line

[0157] SB process room sensor data set / layer image

[0158] SDS process room sensor data Sl shift information

[0159] ST coating control data

[0160] TR reference test body

[0161] TS carrier tax data

[0162] TV test body TZ target test body

[0163] V vertical direction

[0164] V1, V2, V3, V4 hardening area

[0165] VM comparison measure

Claims

Patent claims 1. Method for generating control data (PS) for a device (1) for the additive manufacturing of a component (2) in a manufacturing process in which the component (2) is built up in a build area (8) in the form of component layers (B) by selective solidification of build material (13), preferably comprising a metal-based powder, by irradiating the build material (13) with at least one energy beam (22), the method comprising the steps: a) obtaining or generating layer information (Sl) comprising geometric parameters of component layers and / or information on scan vectors of solidification areas (V1, V2, V3, V4) which represent component layers (B) of the component (2), b) selecting or generating a first fill area (F1) for a first solidification area (V1), wherein this fill area (F1) has a fill pattern (FM) of mutually parallel scan vectors (S) with a predetermined vector spacing,c) Creating a second fill area (F2) with a fill pattern (FM) consisting of mutually parallel scan vectors (S) for a second solidification area (V2) resting on the first solidification area (V1), wherein the scan vectors (S) of the second fill area (F2) are substantially parallel to and offset from the scan vectors (S) of the first fill area (F1), d) Generating control data (PS) such that the additive manufacturing device (1) can produce component layers (B) according to the solidification areas (V1, V2, V3, V4) using this control data (PS).

2. The method according to claim 1, comprising, after step c) and before step d), the following steps: - Creating a third filling area (F3) from mutually parallel scan vectors (S) for a third solidification area (V3), wherein the third filling area (F3) lies above the first filling area (F1) and at least partially covers it, and wherein the filling pattern (FM) of the third filling area (F3) is rotated relative to the filling pattern (FM) of the first filling area (V3), in particular by a rotation angle of more than 10°, preferably wherein the filling pattern (FM) of the third filling area (F3) is identical to the filling pattern (FM) of the first filling area (F1) except for the rotation; - preferably creating a fourth fill area (F4) from mutually parallel scan vectors (S) for a fourth solidification area (V4) resting on the third solidification area (V3), wherein the scan vectors (S) of the fourth fill area (F4) are essentially aligned parallel to and offset from the scan vectors (S) of the third fill area (F3).

3. A method according to one of the preceding claims, wherein the scan vectors (S) of the second filling area (F2) are shifted in a plane of the second solidification area (V2) relative to the scan vectors (S) of the first filling area (F1) in a transverse direction relative to a longitudinal extent of the scan vectors (S) of the first filling area (F1), wherein the corresponding vector spacings of the filling patterns (FM) of the filling areas (F1, F2) are identical, preferably wherein a displacement distance in the transverse direction is less than the vector spacing between two scan vectors (S), and preferably lies in the range between 90% and 10% of the vector spacing, and particularly preferably lies in the range between 45% and 55% of the vector spacing, and preferably is less than 0.1 mm.

4. Method according to one of the preceding claims, wherein a fill pattern (FM) is made of - a hatching pattern consisting of a large number of mutually parallel scan vectors (S) or - a contour consisting of mutually parallel scan vectors (S) or - is formed from a circular or spiral arrangement of a number of scan vectors (S).

5. Method according to one of the preceding claims, wherein in superimposed solidification areas (V1 , V2, V3, V4) - Fill areas (F1, F2, F3, F4) essentially cover the entire surface, preferably with fill areas (F1, F2, F3, F4) having an identical shape and size essentially covering each other completely, and / or - Fill areas (F1, F2, F3, F4) are arranged offset from each other, preferably wherein fill areas (F1, F2, F3, F4) with a similar or identical fill pattern (FM) are shifted from each other along the scan vectors (S) by a predetermined displacement distance, and / or - Fill areas (F1, F2, F3, F4) are arranged rotated relative to each other without their fill patterns (FM) being rotated as well, and / or - The fill pattern (FM) of overlapping fill areas (F1, F2, F3, F4) differs from each other with respect to an offset longitudinally and / or transversely to their scan vectors (S), and / or with respect to a rotation of their scan vectors (S), preferably wherein a displacement distance in the longitudinal direction is less than a strip width of a fill area (F1, F2, F3, F4) in the form of a hatched strip, and preferably lies in the range between 90% and 10% of the strip width, and particularly preferably in the range between 45% and 55% of the strip width, and / or preferably wherein a displacement in the transverse direction, particularly according to claim 2, and in the longitudinal direction takes place, the displacement distance of which is less than a diagonal extent of the first fill area (F1) and preferably lies in the range between 90% and 10% of the diagonal extent, and particularly preferably in the range between 45% and 55% of the diagonal extent lies.

6. Method according to one of the preceding claims, wherein within a filling area (F1, F2, F3, F4) and / or between two directly superimposed filling areas (F1, F2, F3, F4) the values ​​of a number of parameters, in particular a velocity, a power, a pulse pattern and / or an intensity distribution, of the energy beam (22) for solidifying a build-up material during solidification along the scan vectors (S) are changed, wherein in particular the respective values ​​of the number of parameters change between the first filling area (F1) and the second filling area (F2) and / or the third filling area (F3) and the fourth filling area (F4).

7. Method according to one of the preceding claims, wherein the control data (PS) are generated such that the energy beam (22) is adjusted to solidify an area deeper than the thickness of the respective last component layer (B) during solidification along the scan vectors (S), preferably at least twice, more preferably at least three times, particularly preferably at least four times this thickness, and in particular having a depth of hardening greater than 0.05 mm, preferably wherein the hardening is carried out in the form of a deep penetration welding process.

8. A method according to any of the preceding claims, wherein a quality measure is determined from a comparison of pores of test specimens, comprising the steps: - Manufacturing a target test specimen (TZ) with control data (PS) which has been created using a method according to one of the preceding claims, - Producing a reference test body (TR) with control data (PS) at least without an offset arrangement of scan vectors (S) according to step c) of the procedure, - Determining parameter values ​​for parameters of pores (P) of the target test specimen (TZ) and the reference test specimen (TR) using the same measurement method, wherein the parameter values ​​of the pores (P) include in particular their size and / or number, - Creating a comparative measure (CM) of the determined parameter values ​​of the target test specimen (TC) and the reference test specimen (TR), - Optional: Production of test specimens (TV) with control data (PS) using a method according to one of the preceding claims, wherein layer information (Sl) is generated or modified such that a vector spacing of scan vectors (S) of the fill areas (F1, F2, F3, F4) to each other and / or a scan speed for these scan vectors (S) is increased and - Optional: Investigating changes in the comparative measure (VM) by comparing the experimental test specimens (TV) with the reference test specimen (TR) in relation to the layer information (Sl) and creating a comparative measure (VM) as a function of the layer information (Sl). - Creating the quality measure (Q) based on a number of created comparison measures (VM).

9. Method according to claim 8, wherein, based on the quality measure (Q), which in particular includes information about a ratio to layer information (Sl), the obtained or generated layer information (Sl) is modified by increasing the vector spacing of scan vectors (S) of the fill areas (F1, F2, F3, F4) to each other and / or by increasing the scan speed for these scan vectors (S), and the steps of the method are carried out based on the modified or generated layer information (Sl).

10. Control data (PS) for controlling a device (1) for additive manufacturing, which have been generated according to a method according to one of the preceding claims.

11. Manufacturing process for the additive manufacturing of a component (2), wherein in a build field (8) the component (2) is built up layer by layer in the form of component layers (B) by selective solidification of build material (13), preferably comprising a metal-based powder, by irradiating the build material (13) with at least one energy beam (22) is built up according to the control data (PS) according to claim 10, wherein the energy beam (22) is moved over the build area (8) according to the control data (PS) to create component layers (B) of the component (2).

12. Control data generation device (34) for generating control data (PS) according to claim 10 for a device (1) for additive manufacturing of a component (2) in a manufacturing process in which the component (2) is built up in a build field (8) in the form of component layers (B) by selective solidification of build material (13), preferably comprising a metal-based powder, by irradiating the build material (13) with at least one energy beam (22), the control data generation device (34) comprising: - a data interface (35) designed to receive layer information (Sl) comprising geometric parameters of component layers and / or information on scan vectors of hardening areas (V1, V2, V3, V4) which represent component layers (B) of the component (2), - a control module (36) designed for i) selecting or generating a first filling area (F1) for a first consolidation area (V1), wherein this filling area (F1) has a filling pattern (FM) of mutually parallel scan vectors (S) with a predetermined vector spacing, ii) creating a second filling area (F2) with a filling pattern (FM) of mutually parallel scan vectors (S) for a second consolidation area (V2) lying on the first consolidation area (V1), wherein the scan vectors (S) of the second filling area (F2) are substantially, preferably exactly, aligned parallel to and offset from the scan vectors (S) of the first filling area (F1), - a control data generation unit (37) designed to generate control data (PS) such that the device (1) for additive manufacturing can produce component layers (B) according to the solidification areas (V1 , V2, V3, V4) using this control data (PS).

13. Control device (30) for a device (1) for the additive manufacturing of a component (2) in a manufacturing process in which the component (2) is built up layer by layer in a build area (8) in the form of component layers (B) by selective solidification of build material (13), preferably comprising a metal-based powder, by means of irradiation of the The build-up material (13) is constructed with at least one energy beam (22) by means of an irradiation device (20), wherein the control device (30) is configured to control the device (1) for the additive manufacturing of the component layers (B) of the component (2) according to control data (PS) according to claim 10, wherein the control device (30) preferably comprises a control data generation device (34) according to claim 12.

14. Device (1) for the additive manufacturing of at least one component (2) in an additive manufacturing process with at least - a feeding device for applying layers of build material (13) to a build area in a process chamber (3), - an irradiation device (20) to selectively solidify build-up material (13) by irradiation with at least one energy beam (22), in particular between the application of two material layers, and - a control device (30) according to claim 13.

15. Computer program product comprising instructions which, when the program is executed by a computer, cause it to perform the steps of the method according to any one of claims 1 to 9 and / or 11.

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