Method and planning device for planning a locally selective irradiation of a working region using a plurality of energy beams, method and manufacturing device for the additive manufacturing of a component from a pulverulent material, and computer program

Abstract

The invention relates to a method for planning a locally selective irradiation of a working region (11) using a first number of energy beams (7) in order to produce, using the energy beams (7), at least one component layer-by-layer from a plurality of layers of a pulverulent material, the layers being provided successively over time in a layer sequence in the working region (11), wherein - at least one cross-section (17) of at least one component to be produced is determined or provided in at least one planning layer of the plurality of pulverulent material layers, - irradiation vectors (19) are planned in the at least one component cross-section (17) such that a second number of irradiation regions (16) are formed comprising the irradiation vectors (19), the second number equaling the first number, and in particular - an irradiation plan is obtained for the locally selective irradiation of the working region (11) using the energy beams (7) in the at least one pulverulent material planning layer.

Description

[0001] DESCRIPTION

[0002] Method and planning device for planning a locally selective irradiation of a work area with a plurality of energy beams, method and manufacturing device for the additive manufacturing of a component from a powder material and computer program

[0003] The invention relates to a method and a planning device for planning a locally selective irradiation of a work area with a plurality of energy beams, a method and a manufacturing device for the additive manufacturing of components from a powder material and a computer program.

[0004] Typically, when planning locally selective irradiation of a work area, irradiation vectors are generated in a first step, independent of the number of available energy beams. Subsequently, in a second step, the generated energy beams are manipulated depending on the number of energy beams, in particular by being divided among different energy beams or areas fixed to them, and, if necessary, split into smaller irradiation vectors, especially if an irradiation vector crosses a boundary between two areas assigned to different energy beams. In this respect, it is typically intended that the work area of ​​a manufacturing device is fixed and independent of the specific component geometry to be manufactured, divided into different areas that are assigned to different energy beams.In some cases, this method generates very small radiation vectors. The problem here is that the utilization of the various energy beams is often suboptimal, resulting in low productivity. Furthermore, the division of radiation vectors along predetermined boundaries, and especially the generation of very small radiation vectors, can lead to quality problems in the manufactured components.

[0005] The invention is therefore based on the objective of creating a method and a planning device for planning a locally selective irradiation of a work area with a plurality of energy beams, a method and a manufacturing device for the additive manufacturing of components from a powder material and a computer program, wherein the aforementioned disadvantages are at least reduced, preferably avoided.

[0006] The problem is solved by providing the present technical teaching, in particular the teaching of the independent claims as well as the embodiments disclosed in the dependent claims and the description.

[0007] The problem is solved in particular by creating a method – hereinafter referred to as a planning method – for planning a locally selective irradiation of a work area with a first number of energy beams in order to produce at least one component layer by layer from a plurality of powder material layers arranged successively in a layer sequence in the work area.

[0008] - wherein in at least one planning powder material layer the majority of

[0009] Powder material layers at least one component cross-section of at least one component to be manufactured is determined or provided, wherein

[0010] - in which at least one component cross-section radiation vectors are planned in such a way that a second number encompassing the radiation vectors

[0011] Irradiation areas are formed, where the second number is equal to the first number.

[0012] The second set of irradiation zones is formed, in particular, within the at least one component cross-section. Because the first set of energy beams is already considered during the planning phase, i.e., when generating the irradiation vectors, the irradiation vectors can be optimally planned based on the known number of energy beams. In particular, the subsequent division of irradiation vectors, and thus the creation of extremely short irradiation vectors, can be avoided, resulting in high component quality. By choosing the second set of irradiation zones to be the same as the first, the energy beams are utilized as efficiently as possible, preferably evenly, thus ensuring high productivity.This is especially true because the irradiation areas are not defined independently of the component geometry on the working area, but rather are formed in the cross-section of at least one component.

[0013] The first number of energy beams corresponds specifically to the total number of available energy beams, that is, the total number of energy beams of the manufacturing device for which the planning procedure is carried out. Therefore, if the second number of irradiation zones is equal to the first number of energy beams, as many irradiation zones are planned as there are available energy beams.

[0014] It is possible, but not mandatory, for the irradiation vectors and irradiation areas to be assigned to a specific energy beam during their generation; this can also be done in a subsequent step. It is important that the first number equals the second number.

[0015] In particular, the second number is exactly the same – that is, identical – to the first number.

[0016] In the context of this technical teaching, a component cross-section is understood to be, in particular, a cross-sectional area of ​​a component to be manufactured, located within the planning powder layer, that is to be irradiated. The cross-sectional area to be irradiated, and thus the component cross-section, preferably includes areas of support structures or the like that are to be removed later. Therefore, the area to be irradiated is considered to be the entire component to be manufactured, regardless of whether a specific structure belonging to this area is part of the component itself or represents an auxiliary structure.

[0017] It is possible that more than one component cross-section is taken into account, whereby - as explained in more detail below - depending in particular on the relative arrangement of a plurality of component cross-sections to each other, the second number is counted for a component cross-section alone or for several component cross-sections together.

[0018] The cross-section of at least one component can be determined, which means, in particular, that determining the component cross-section is part of the planning process. The cross-section of at least one component is determined, in particular, by decomposing a geometry of the component to be manufactured, given, for example, in the form of CAD data, into a plurality of component layers, with each component layer being assigned a layer of powder material. In the additive manufacturing of a component from a powder material, a section of the component to be manufactured is solidified layer by layer by locally melting the powder material in each of a plurality of powder material layers. For this purpose, the three-dimensional object to be manufactured is virtually decomposed into a plurality of component layers, with each component layer being assigned a layer of powder material from the plurality of powder material layers.

[0019] The cross-section of at least one component can also be provided; in this case, the determination of the component cross-section itself is not part of the planning process, but the component cross-section is generated in a process step preceding the planning process described here and is merely obtained or received for the planning process.

[0020] In the context of this technical teaching, the fact that irradiation vectors are planned in at least one component cross-section means, in particular, that previously non-existent irradiation vectors are planned; that is, the irradiation vectors are newly planned, i.e., newly generated. This, in turn, means, in particular, that the planning process does not involve manipulating previously generated irradiation vectors, but rather generating new irradiation vectors—as it were, ex ovo, de novo, or ab initio.

[0021] When planning the irradiation vectors, at least one vector parameter is specified, which is selected from a group consisting of an irradiation vector length, an irradiation vector width, a distance between two irradiation vectors immediately adjacent to each other perpendicular to their extension (also called track spacing), and a combination of at least two of the aforementioned vector parameters.

[0022] Preferably, a radiation plan for the locally selective irradiation of the work area with the energy beams is obtained in the at least one planning powder material layer, particularly as a result or product of the planning process.

[0023] Additive or generative manufacturing of a component is understood to mean, in particular, the layer-by-layer construction of a component from powder material, especially a powder bed-based process for manufacturing a component in a powder bed, and in particular a manufacturing process selected from the group consisting of selective laser sintering, laser metal fusion (LMF), direct metal laser melting (DMLM), laser net shaping manufacturing (LNSM), selective electron beam melting (SEBM), and laser engineered net shaping (LENS). The manufacturing device is therefore specifically configured to carry out at least one of the aforementioned additive or generative manufacturing processes.

[0024] The energy beams are each selected from a group consisting of an electromagnetic beam, in particular an optical working beam, in particular a laser beam, and a particle beam, in particular an electron beam. At least one of the energy beams can be continuous or pulsed, in particular continuous laser radiation or pulsed laser radiation. In one embodiment, all energy beams are identical, in particular all being laser beams.

[0025] An irradiation vector is understood to be, in particular, a continuous, preferably linear, displacement of the energy beam over a specific distance with a specific displacement direction. The irradiation vector includes, in particular, the direction or orientation of the displacement, that is, the vector alignment. The irradiation vector need not be a straight line segment; rather, an irradiation vector can also follow a line or curve that is at least partially curved. In particular, an irradiation vector is understood to be a corresponding instruction for controlling a scanner device designed to displace the energy beam.

[0026] In the context of the present technical teaching, the processing of an irradiation vector is understood in particular to mean that the scanner device is controlled and / or the energy beam is actually moved within the working area in accordance with the definition given by the irradiation vector.

[0027] An irradiation area is understood to be, in particular, a contiguous region that comprises a subset of the irradiation vectors, whereby the irradiation area as a whole, that is, all irradiation vectors arranged within the irradiation area, are assigned or will be assigned to one of the energy beams. As already explained above, this assignment does not have to be made during the generation of the irradiation vectors and irradiation areas, but can also be made subsequently. The only important thing is that the irradiation vectors assigned to a common irradiation area are assigned to a common energy beam or are intended to be assigned to a common energy beam.In particular, the irradiation plan is obtained as a data set for controlling a manufacturing device, especially a manufacturing device according to the invention as described below, or a manufacturing device according to one or more of the embodiments described below, for the additive manufacturing of a component from the powder material. Regardless of whether the method is carried out on a planning device arranged separately from a manufacturing device or on the manufacturing device itself, the irradiation plan is thus obtained in an easily manageable, and in particular machine-readable, form. It is also preferably possible to export the irradiation plan obtained as a data set and to transport it, and in particular to transmit it, independently of a specific device, for example, embodied on a data carrier or virtually via a network.

[0028] According to a further development of the invention, the individual energy beams are assigned to the irradiation areas during the planning of the irradiation vectors. In this case, the assignment takes place directly during the generation of the irradiation vectors. This is a very economical approach, which in particular eliminates the need for any subsequent intervention by the user.

[0029] Alternatively, the individual energy beams can be assigned to the irradiation areas after the irradiation vectors have been planned. This advantageously represents a particularly flexible approach, where the assignment can be selected or changed subsequently, especially depending on specific manufacturing conditions. The assignment of the irradiation vectors can be carried out by a user, particularly an end user. Furthermore, the assignment can be performed manually or automatically.

[0030] According to a further development of the invention, the irradiation vectors are planned such that the total vector length of the irradiation vectors assigned to each irradiation area is the same for all irradiation areas. In particular, this advantageously results in a homogeneous utilization of the various energy beams. The total vector length is understood to be, in particular, the sum of the individual vector lengths of all irradiation vectors within an irradiation area. If the total vector lengths in the respective irradiation areas are at least substantially the same, the working time and thus the utilization of the respective assigned energy beams are also substantially the same. The fact that the irradiation vectors are planned in a specific way means, here and in the following, in particular that the irradiation vectors are planned with the planning objective corresponding to this specific method.This does not mean that the planning objective must always be achieved through the planning process – especially not in its entirety. However, achieving the planning objective is preferred.

[0031] The fact that a certain quantity is the same for all irradiation ranges or for all energy beams means, here and in the following, in particular, that the correspondingly designated quantity is at least substantially the same for all irradiation ranges or energy beams. Preferably, the quantity is exactly the same for all irradiation ranges or energy beams.

[0032] Alternatively or additionally to the planning objective of achieving at least substantially the same total vector length, the irradiation vectors are planned such that the number of irradiation vectors assigned to each irradiation area is the same for all irradiation areas. This approach also advantageously results in the most homogeneous possible utilization of the different energy beams.

[0033] According to a further development of the invention, the energy beams are assigned to the irradiation areas during the planning of the irradiation vectors, whereby the irradiation vectors are planned in such a way that the total working time of the individual energy beams in the planning powder material layer is the same for all energy beams. In particular, a homogeneous utilization of the different energy beams is achieved directly in this way.

[0034] Alternatively or additionally, the irradiation vectors are planned such that the respective power of the energy beams is taken into account during the planning of the irradiation vectors. In this case, if the powers of the different energy beams differ from one another, it is advantageous to deviate from an equal distribution of the irradiation vectors, in particular their total vector length or number, especially to homogenize the actual utilization of the different energy beams. In particular, a distribution weighted according to the power of the energy beams is preferably carried out. In this case, energy beams with higher power are preferably assigned a greater total vector length or a greater number of irradiation vectors, while energy beams with lower power are assigned a smaller total vector length or a smaller number of irradiation vectors.The underlying principle is that a higher-powered energy beam can process a given irradiation vector faster than a lower-powered energy beam. By weighting the distribution according to power, the total working time, and thus the utilization, can be distributed at least essentially homogeneously across the different energy beams.

[0035] According to a further development of the invention, it is provided that the irradiation parameters for the irradiation vectors are determined temporally after their planning. Advantageously, the initial number of energy beams can be taken into account when determining the irradiation parameters. In particular, the heat input into the component is highly dependent on the number of energy beams operating in parallel over time, so the irradiation parameters are sensibly adjusted accordingly in order to prevent, in particular, overheating or cooling of certain zones of the resulting components.

[0036] At least one irradiation parameter is preferably selected from a group consisting of a line energy, a displacement velocity of an energy beam along an irradiation vector, a beam shape of the energy beam on the planning powder material layer, a beam size, in particular beam diameter, of the energy beam on the planning powder material layer, and a combination of at least two of the aforementioned irradiation parameters.

[0037] In one embodiment, the irradiation parameters are also determined temporally after the energy beams have been assigned to the irradiation areas. Advantageously, this allows the assignment of the irradiation areas to the energy beams to be taken into account when determining the irradiation parameters. In particular, the heat input into the component is also highly dependent on the specific arrangement of the energy beams operating in parallel over time, so the irradiation parameters are sensibly adjusted accordingly in order to prevent, in particular, overheating or cooling of certain zones of the resulting components.

[0038] According to a further development of the invention, the irradiation vectors are planned in the planning powder material layer according to a preferred direction for processing the irradiation vectors such that, if at least two component cross-sections are arranged next to each other transversely – in particular perpendicularly – to the preferred direction, the second number of irradiation vectors is distributed between the at least two adjacent component cross-sections. Thus, all energy beams can advantageously operate simultaneously – in particular at approximately the same, common height along the preferred direction – in the direction of the preferred direction.

[0039] The preferred direction is defined, in particular, with respect to the flow direction of a protective gas stream across the working area and thus the planning powder material layer; preferably, the preferred direction extends against the flow direction. If all energy jets operate simultaneously – especially at the same, common height – along the preferred direction, it can advantageously be avoided that soot and smoke carried away by the protective gas stream negatively affect the ongoing manufacturing process.

[0040] Alternatively or additionally, the irradiation vectors are planned in the planning powder layer for processing, depending on the preferred direction, such that if at least one first component is arranged in cross-section along the preferred direction in front of at least one second component, the second number of irradiation areas is obtained once for the at least one first component cross-section and once for the at least one second component cross-section. In this way, the energy beams can also operate simultaneously – and in particular, always at the same, common height – along the preferred direction.

[0041] According to a further development of the invention, the method is carried out for a plurality of planning powder material layers. In one embodiment, the method is carried out for all powder material layers of the plurality of powder material layers as planning powder material layers. Preferably, the method is thus carried out for a plurality of planning powder material layers of the powder material layers required for the production of the component, which are successively arranged in the working area, and particularly preferably for all powder material layers. This means, in particular, that preferably each powder material layer is treated as a planning powder material layer within the framework of the method. Depending on the specific implementation of the planning method on a computing device, this can be done successively one after the other, or at least partially simultaneously.Optimizing the irradiation can also involve cyclic or iterative treatment of the powder material layers as planning powder material layers in the process.

[0042] The problem is also solved in a second aspect, in particular, by creating a method – hereinafter referred to as a manufacturing process – for the additive manufacturing of a component from a powder material, comprising the following steps: providing an irradiation plan obtained by means of a planning method according to the invention or a planning method according to one or more of the embodiments described above for the locally selective irradiation of a working area with a plurality – the first number – of energy beams, in order to produce the component layer by layer from a plurality of powder material layers arranged successively in a layer sequence in the working area, and manufacturing the component according to the irradiation plan.The manufacturing process offers, in particular, those advantages that were previously explained in connection with the planning process.

[0043] In one embodiment, the irradiation plan is provided by carrying out a planning method according to the invention or a planning method according to one or more of the embodiments described above. Thus, the manufacturing process also includes the planning method – particularly in the form of steps preceding the actual manufacturing.

[0044] Preferably, laser beams or electron beams are used as the energy beams.

[0045] Preferably, the component is manufactured using selective laser sintering and / or selective laser melting.

[0046] Preferably, a metallic or ceramic powder can be used as the powder material.

[0047] The problem is also solved in a third aspect, in particular, by creating a computer program comprising machine-readable instructions that cause a computing device, especially a planning device or a control device of a manufacturing device on which the computer program runs, to carry out a planning method according to the invention or a planning method according to one or more of the previously described embodiments, or a manufacturing method according to the invention or a manufacturing method according to one or more of the previously described embodiments. In connection with the computer program, the advantages that arise are those already explained in connection with the planning method or the manufacturing method.The invention also includes a machine-readable storage medium comprising a computer program according to the invention or a computer program according to one or more of the embodiments described above. In connection with the storage medium, the advantages are particularly those already explained in connection with the planning method, the manufacturing method, or the computer program.

[0048] In a fourth aspect, the problem is also solved, in particular, by creating a planning device for planning a locally selective irradiation of a work area with a plurality – the first number – of energy beams in order to produce a component from a powder material arranged in the work area using the energy beams, wherein the planning device is configured to carry out a planning method according to the invention or a planning method according to one or more of the embodiments described above. In connection with the planning device, the advantages are particularly those that have already been explained in connection with the planning method, the manufacturing method, the computer program, or the storage medium.

[0049] In one embodiment, the planning device is configured as a device selected from a group consisting of a computer, in particular a personal computer (PC), a plug-in card or control card, and an FPGA board. In another embodiment, the planning device is an RTC control card of SCANLAB GmbH, in particular in the configuration currently available on the date determining the priority date of the present patent right.

[0050] In particular, the planning device can be provided externally or separately from a manufacturing device, wherein the planning device preferably creates a data set which is then transmitted in a suitable manner, for example by means of a data carrier or via a network, in particular via the Internet, or via another suitable wireless or wired transmission method, to a manufacturing device, in particular a control device of a manufacturing device. For example, it is possible that the planning device generates CAM data from CAD data, i.e., in particular a sequence of commands, in particular an NC program, for controlling the manufacturing device, wherein this sequence of commands is then transmitted to the manufacturing device for its control.It is also possible for CAD data of a component to be transferred to the planning device, which then generates the command sequence for the manufacturing device. The planning device can also be integrated into a manufacturing device. In particular, the planning device can be integrated into the control device of the manufacturing device, or the control device of the manufacturing device can be designed as a planning device, especially by providing a suitable hardware component and / or by implementing a suitable computer program, particularly software.For example, CAD data of a component to be manufactured can be transferred to the manufacturing device, with the manufacturing device itself, particularly the planning device implemented in the control device, generating corresponding CAM data or a command sequence for controlling the manufacturing device from the CAD data. However, it is also possible for the planning device to comprise a plurality of computing devices, which are preferably physically distributed. Preferably, the planning device then comprises a plurality of interconnected computing devices. In particular, the planning device can be designed as a data cloud, or the planning device can be part of a data cloud.In a preferred embodiment, it is also possible for the planning device to comprise, on the one hand, at least one computing device external to the manufacturing device and, on the other hand, the manufacturing device, in particular the control device of the manufacturing device, wherein steps performed by the planning device are then carried out partly on the external computing device and partly on the manufacturing device, in particular on the control device. In particular, it is also possible for the planning device not to undertake the complete planning of the locally selective irradiation of the work area, but only parts thereof; in particular, it is possible for the planning device to undertake only that part of the planning of the locally selective irradiation of the work area that relates to the steps and / or specifications described above.Other parts of the planning for locally selective irradiation can, however, be carried out in other computing devices, in particular in computing devices external to the manufacturing device, or even in the manufacturing device itself, in particular its control device, or even in a data cloud. In particular, it is possible for the planning device to modify, adapt, or correct CAM data or a command sequence, in particular an NC program, generated by another computing device. In a sixth aspect, the task is also solved, in particular, by creating a manufacturing device for the additive manufacturing of components from a powder material.

[0051] - at least one beam-generating device designed to generate a plurality - the first number - of energy beams,

[0052] - at least one scanner device configured to selectively irradiate a working area with energy beams in order to produce a component from the powder material arranged in the working area using the energy beams, and with a control device operatively connected to and configured with the at least one scanner device to control the at least one scanner device, wherein the control device is configured to carry out a manufacturing process according to the invention or a manufacturing process according to one or more of the embodiments described above.

[0053] In connection with the manufacturing device, the advantages are particularly those that have already been explained in connection with the planning process, the manufacturing process, the computer program, the storage medium or the planning device.

[0054] In one embodiment, the beam generation device is configured to generate multiple energy beams, and / or the manufacturing device comprises multiple beam generation devices for generating multiple energy beams. It is possible that multiple scanner devices are provided for the multiple energy beams. However, it is also possible that the scanner device is configured to relocate the multiple energy beams—particularly independently of one another—within the work area. In particular, the scanner device can comprise multiple separately controllable scanners, especially scanner mirrors, for this purpose.

[0055] The scanner device preferably comprises at least one scanner, in particular a galvanometer scanner, piezo scanner, polygon scanner, or MEMS scanner, and / or at least one work head or processing head that can be moved relative to the working area. The scanner devices proposed here are particularly suitable for moving the energy beams within the working area.

[0056] A work head or processing head that can be moved relative to the work area is understood here to be, in particular, an integrated component of the manufacturing device which has at least one radiation outlet for at least one energy beam, wherein the integrated component, i.e., the work head, as a whole can be moved relative to the work area along at least one direction of movement, preferably along two perpendicular directions of movement. Such a work head can, in particular, be designed in a gantry configuration or be guided by a robot. In particular, the work head can be designed as the robot hand of a robot.

[0057] The control device is preferably selected from a group consisting of a computer, in particular a personal computer (PC), a plug-in card or control card, and an FPGA board. In a preferred embodiment, the control device is an RTC control card from SCANLAB GmbH, in particular in the embodiment currently available on the date determining the priority date of this patent.

[0058] The control device can itself be designed as the planning device or can include the planning device.

[0059] Preferably, the at least one beam-generating device comprises at least one laser. At least one energy beam—preferably all energy beams—is / are thus advantageously generated as an intense beam of coherent electromagnetic radiation, in particular coherent light. Irradiation in this context preferably means exposure.

[0060] The manufacturing device is preferably configured for selective laser sintering. Alternatively or additionally, the manufacturing device is configured for selective laser melting. These configurations of the manufacturing device have proven to be particularly advantageous.

[0061] According to a further development of the invention, the manufacturing device includes a protective gas device which is set up to generate a protective gas flow with a defined flow direction over the working area.

[0062] The invention will be explained in more detail below with reference to the drawing. The drawing shows:

[0063] Figure 1 shows a schematic representation of an embodiment of a manufacturing device with a planning device;

[0064] Figure 2 is a schematic representation of an example of a planning procedure for planning a locally selective irradiation of a work area with a plurality of energy beams according to the prior art, and Figure 3 is a schematic representation of an embodiment of the planning procedure.

[0065] Fig. 1 shows a schematic representation of an embodiment of a manufacturing device 1 for the additive manufacturing of components from a powder material 2 with a planning device 3.

[0066] The manufacturing device 1 comprises at least one beam generating device 5, preferably designed as a laser, shown here as a first beam generating device 5.1 and a second beam generating device 5.2, which are configured to generate a plurality – the first number – of energy beams 7, in particular laser beams, here a first energy beam 7.1 and a second energy beam 7.2, as well as a scanner device 9, specifically shown as a first scanner device 9.1 and a second scanner device 9.2, which are configured to irradiate a working area 11 locally and selectively with the energy beams 7 in order to produce a component from the powder material 2 arranged in the working area 11 by means of the energy beams 7. Furthermore, the manufacturing device 1 comprises a control device 13, which is operatively connected to the scanner devices 9 and configured to control the scanner devices 9.The control device 13 is configured to carry out a manufacturing process described in more detail below. In particular, the control device 13 includes the planning device 3 or is itself configured as the planning device 3.

[0067] The manufacturing device 1 preferably has a protective gas device 15 which is set up to generate a protective gas flow with a defined flow direction over the working area 11 as schematically represented by a first arrow PI.

[0068] The energy beams 7 preferably work together - especially at the same height - along a preferred direction which here extends against the direction of flow of the protective gas flow, the preferred direction being represented by a second arrow P2.

[0069] Fig. 2 shows a schematic representation of an example of a planning method for planning the locally selective irradiation of the work area 11 with a plurality of energy beams 7 according to the prior art. Identical and functionally equivalent elements are designated with the same reference numerals in all figures, so that reference is made to the preceding description in each case. Furthermore, identical elements that are shown multiple times are marked with the corresponding reference numeral only once for the sake of clarity.

[0070] In the example shown here, four energy beams 7 are provided; in particular, the manufacturing device 1 has exactly four energy beams 7. Typically, the working area 11 is pre-divided—without knowledge of the specific components to be manufactured—into irradiation zones 16, each of which is permanently assigned to the energy beams 7. Here, four irradiation zones 16 are separated from each other by dashed lines and numbered with Roman numerals from I to IV. Furthermore, for each component cross-section 17, irradiation vectors 19 are pre-planned in each powder material layer—without considering the initial number of energy beams 7 and without considering the specific position of the component cross-section 17 in the working area 11. Such pre-planned irradiation vectors 19 in the component cross-sections 17 are schematically represented here by dashed lines.In a subsequent step, the irradiation vectors 19 planned in this way are then divided according to the position of the component cross-sections 17 in the predefined irradiation areas 16, whereby two irradiation vectors 19.1' and 19.2' divided accordingly are shown schematically here.

[0071] As already explained, each of the irradiation areas 16 is assigned exactly one of the energy beams 7. Taking into account the most simultaneous possible displacement of the energy beams 7 along the preferred direction, this results in only two of the four energy beams 7 operating in the area of ​​a first component cross-section 17.1, while the other two energy beams 7 are inactive.

[0072] Two further component cross-sections 17.2 and 17.3 are also shown. In these areas, three of the energy beams 7 are active, while one remaining energy beam 7 is paused.

[0073] Thus, productivity is low with this approach, and it also becomes clear that problems in component quality can arise from the division of the irradiation vectors 19 if very short irradiation vectors 19 are formed. Fig. 3 shows a schematic representation of an embodiment of the planning procedure for planning the locally selective irradiation of the work area 11 with the first number of energy beams 7.

[0074] In the planning process, at least one component (cross-section 17) of at least one component to be manufactured is determined or provided in at least one planning powder material layer of the plurality of powder material layers. Irradiation vectors 19 are planned in this component (cross-section 17) such that a second number of irradiation zones 16, separated here by dashed lines and encompassing the irradiation vectors 19, are formed in the component (cross-section 17), with the second number being equal to the first. The irradiation vectors 19 can thus be optimally planned, and subsequent subdivision of the irradiation vectors 19 can be avoided, resulting in high component quality. Furthermore, the energy beams 7 are utilized as efficiently as possible, preferably uniformly, thus ensuring high productivity.

[0075] It is possible that the individual energy beams 7 are assigned to the irradiation areas 16 during the planning of the irradiation vectors 19. In this case, the assignment takes place directly during the generation of the irradiation vectors 19. Alternatively, the individual energy beams 7 can also be assigned to the irradiation areas 19 only after the planning of the irradiation vectors 19.

[0076] Preferably, the irradiation vectors 19 are planned such that the total vector length of the irradiation vectors 19 assigned to each irradiation area 16 is the same for all irradiation areas 16. Alternatively or additionally, the irradiation vectors 19 are planned such that the number of irradiation vectors 19 assigned to each irradiation area 16 is the same for all irradiation areas 16. In an embodiment in which the energy beams 7 are already assigned to the irradiation areas 16 during the planning of the irradiation vectors 19, the irradiation vectors 19 can be planned such that the total working time of the individual energy beams 7 in the planning powder material layer is the same for all energy beams 7. Alternatively or additionally, the irradiation vectors 19 are planned such that the respective power of the energy beams 7 is taken into account during the planning of the irradiation vectors 19.

[0077] Preferably, irradiation parameters for the irradiation vectors 19 are determined after their planning, and preferably also after the energy beams 7 have been assigned to the irradiation areas 16. At least one irradiation parameter is preferably selected from a group consisting of a line energy, a displacement velocity of the assigned energy beam 7 along an irradiation vector 19, a beam shape of the assigned energy beam 7 on the planning powder material layer, a beam size, in particular beam diameter, of the assigned energy beam 7 on the planning powder material layer, and a combination of at least two of the aforementioned irradiation parameters.

[0078] The first component cross-section 17.1 illustrates that the irradiation vectors 19 are preferably planned in the planning powder material layer for their processing, depending on the preferred direction, such that—if, as here, the first component cross-section 17.1 is arranged alone along the preferred direction in front of at least one further component cross-section 17, here the second and third component cross-sections 17.2, 17.3—the second number of irradiation zones 16 is obtained once for the at least one first component cross-section 17.1 and again for the second and third component cross-sections 17.2, 17.3. In particular, the first component cross-section 17.1 comprises four irradiation zones 16. In this way, the energy beams 7 can all operate simultaneously—especially always at the same, common height—along the preferred direction.

[0079] Based on the second and third component cross-sections 17.2, 17.3, it is shown that the irradiation vectors 19 are preferably planned in the planning powder material layer for the processing of the irradiation vectors 19, depending on the preferred direction, such that the second number of irradiation zones 16 is distributed between the second and third component cross-sections 17.2, 17.3, which are arranged side by side transversely to the preferred direction. In particular, the second component cross-section 17.2 and the third component cross-section 17.3 together comprise four irradiation zones 16, and in particular, each component cross-section 17.2, 17.3 comprises two irradiation zones 16. Thus, here too, all energy beams 7 can advantageously act simultaneously – in particular at approximately the same, common height along the preferred direction – in the direction of the preferred direction.

[0080] The planning procedure is preferably carried out for a plurality of planning powder material layers, in particular for all powder material layers of the plurality of powder material layers as planning powder material layers. A manufacturing process for the additive manufacturing of a component from a powder material preferably comprises the following steps: providing an irradiation plan obtained by means of the planning procedure for the locally selective irradiation of the working area 11 with the first number of energy beams 7, in order to produce the component layer by layer from a plurality of powder material layers of the powder material arranged sequentially in a layer sequence in the working area 11, and manufacturing the component according to the irradiation plan. Preferably, the irradiation plan is provided by carrying out the planning procedure.Thus, the manufacturing process also includes the planning process – particularly in the form of steps preceding the actual manufacturing.

Claims

REQUIREMENTS 1. Method for planning a locally selective irradiation of a working area (11) with a first number of energy beams (7) in order to produce at least one component layer by layer from a plurality of powder material layers arranged successively in a layer sequence in the working area (11) by means of the energy beams (7), - wherein in at least one planning powder material layer of the majority of powder material layers at least one component cross-section (17) of at least one component to be manufactured is determined or provided, wherein - in which at least one component cross-section (17) irradiation vectors (19) are planned in such a way that a second number of irradiation areas (16) comprising the irradiation vectors (19) is formed, wherein the second number is equal to the first number, and wherein in particular an irradiation plan for the locally selective irradiation of the working area (11) with the energy beams (7) is obtained in the at least one planning powder material layer.

2. Method according to claim 1, wherein the individual energy beams (7) are directed to the irradiation areas (16) - in the planning of the irradiation vectors (19) or - are assigned according to the planning of the irradiation vectors (19).

3. Method according to one of the preceding claims, wherein the irradiation vectors (19) are planned such that the total vector length of the irradiation vectors (19) assigned to the irradiation areas (16) is the same for all irradiation areas (16), and / or the number of irradiation vectors (19) assigned to the irradiation areas (16) is the same for all irradiation areas (16).

4. Method according to one of claims 1 or 3, wherein the energy beams (7) are assigned to the irradiation areas (16) when planning the irradiation vectors (19), and wherein the irradiation vectors (19) are planned such that a total working time of the individual energy beams (7) in the planning powder material layer is the same for all energy beams (7), or a respective power of the energy beams (7) is taken into account when planning the irradiation vectors (19).

5. Method according to one of the preceding claims, wherein irradiation parameters for the irradiation vectors (19) are determined after their planning, and preferably after the assignment of the energy beams (7) to the irradiation areas (16).

6. Method according to one of the preceding claims, wherein the irradiation vectors (19) are planned in the planning powder material layer depending on a preferred direction for the processing of the irradiation vectors (19) such that - if at least two component cross-sections (17) are arranged next to each other transversely to the preferred direction, the second number is divided between the at least two component cross-sections (17) arranged next to each other, and / or - if at least one first component cross section (17) is arranged along the preferred direction in front of at least one second component cross section (17), the second number of irradiation areas (16) is obtained once for the at least one first component cross section (17) and once for the at least one second component cross section (17).

7. Method according to one of the preceding claims, wherein the method is carried out for a plurality of planning powder material layers, preferably for all powder material layers of the plurality of powder material layers.

8. Method for additively manufacturing at least one component from a powder material (2), comprising the following steps: providing an irradiation plan obtained by means of a method according to one of claims 1 to 7 for the locally selective irradiation of a working area (11) with a plurality of energy beams (7) in order to produce the at least one component layer by layer from a plurality of powder material layers of the powder material (2) arranged in a layer sequence in the working area (11) by means of the energy beams (7), and manufacturing the at least one component according to the irradiation plan.

9. Computer program comprising instructions that cause a computing device on which the computer program runs to perform a method according to any one of claims 1 to 8.

10. Planning device (3) for planning a locally selective irradiation of a working area (11) with a plurality of energy beams (7) in order to produce at least one component from a powder material (2) arranged in the working area (11) by means of the energy beams (7), wherein the planning device (3) is set up to carry out a method according to one of claims 1 to 7.

11. Manufacturing device (1) for additive manufacturing of components from a powder material (2), with - at least one beam-generating device (5) which is configured to generate a plurality of energy beams (7), - at least one scanner device (9) configured to locally selectively irradiate a working area (11) with the energy beams (7) in order to produce at least one component from the powder material (2) arranged in the working area (11) by means of the energy beams (7), and with a control device (13) operatively connected to the at least one scanner device (9) and configured to control the at least one scanner device (9), wherein the control device (13) is configured to carry out a method according to claim 8.

12. Manufacturing device (1) according to claim 11, comprising a protective gas device (15) which is configured to generate a protective gas flow with a defined flow direction over the working area (11).

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