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 powder material, and computer program

Abstract

The invention relates to a method for planning locally selective irradiation of a working region (11) with a plurality of energy beams (7) in order to produce, by means of the energy beams (7), at least one component (13) layer by layer from a plurality of powder material layers (21) of a powder material (2) arranged sequentially in time in a layer sequence in the working region (11), wherein, in at least one planning powder material layer (21') of the plurality of powder material layers (21), a plurality of component cross-sections (19) of at least one component (13) to be produced is determined or provided, wherein the component cross-sections (19) are assigned to the energy beams (7) of the plurality of energy beams (7) while optimising at least one optimisation target, wherein the at least one optimisation target is selected from a group consisting of a uniform cross-sectional distribution of the component cross-sections (19) among the energy beams (7), a uniform surface distribution of a total surface to be irradiated in the planning powder material layer (21') among the energy beams (7), a uniform volume distribution of a total powder volume to be solidified of the planning powder material layer (21') among the energy beams (7), a uniform temporal distribution of an activity time among the energy beams (7), a uniform vector length distribution of irradiation vectors among the energy beams (7), and a combination of at least two of said optimisation targets.

Description

[0001] DS16761P4439DE0 1 29.10.2024

[0002] Applicant:

[0003] TRUMPF Laser- und Systemtechnik SE Johann-Maus-Straße 2 71254 Ditzingen

[0004] DESCRIPTION

[0005] 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

[0006] 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.

[0007] Typically, the working area of ​​a manufacturing device for the additive manufacturing of components from a powder material is pre-divided into multiple energy beams without knowledge or consideration of the components actually to be manufactured; for example, a working area can be divided equally between two energy beams. If, in a specific manufacturing process, the components in the various areas assigned to the respective energy beams have very different heights and / or volumes, the utilization and activity time of the respective energy beams can vary considerably. For example, in an extreme case, it is possible that towards the end of the manufacturing process—especially in upper layers of powder material—only a single energy beam is still active in an area containing particularly tall components, while the other energy beams are inactive.This is inefficient both in terms of energy beam utilization and integral process time. A further problem arises because a blanket division of the work area makes it impossible to allocate specific energy beams to specific components; thus, it is possible that one and the same component is formed more or less randomly by different, and sometimes even multiple, energy beams, depending on the specific process planning. This is particularly suboptimal in areas where a DS16761P4439DE0 2 29.10.2024.

[0008] Certification of the manufactured components is required, as regularly reproducible manufacturing conditions are demanded.

[0009] 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.

[0010] The problem is solved by providing the present technical teaching, in particular the teaching of the independent claims and the embodiments disclosed in the dependent claims and the description.

[0011] The task is solved, in particular in a first aspect, by creating a method – hereinafter referred to as a planning method – for planning a locally selective irradiation of a work area with a plurality 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, wherein

[0012] - in at least one planning powder material layer of the majority of powder material layers, a plurality of component cross-sections of at least one component to be manufactured - optionally several components - are determined or provided, wherein

[0013] - the component cross-sections are assigned to the individual energy beams of the majority of energy beams under optimization of at least one optimization goal, and wherein

[0014] - that at least one optimization goal is selected from a group consisting of a uniform cross-sectional distribution of the component cross-sections onto the energy beams, a uniform area distribution of a total area to be irradiated in the planning powder material layer onto the energy beams, a uniform volume distribution of a total powder volume to be solidified in the planning powder material layer onto the energy beams, a uniform temporal distribution of an activity time - in the planning powder material layer - onto the energy beams, a uniform vector length distribution of irradiation vectors DS16761P4439DE0 3 29.10.2024

[0015] - in the planning powder material layer - on the energy beams, and a combination of at least two of the aforementioned optimization goals.

[0016] By considering at least one optimization goal when assigning energy beams to component cross-sections, a more homogeneous utilization of the energy beams is achieved – particularly with components or component areas of varying heights and / or volumes, thereby simultaneously reducing the overall process time. Furthermore, optimizing at least one goal is a transparent and, where applicable, predictable approach that yields correspondingly transparent and, ideally, predictable results. Accordingly, the planning method proposed here is particularly suitable for the production of certified components under reproducible process conditions.

[0017] 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.

[0018] If more than one optimization goal is applied, the optimization goals are given preferential weight and thus prioritized relative to each other.

[0019] In the context of this technical teaching, a component cross-section is understood to be, in particular, the cross-sectional area of ​​a component to be manufactured, located within the design 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 area associated with the 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.

[0020] The various component cross-sections can be assigned to different components or – as so-called islands – to the same component, particularly if a component, due to its complex geometric structure, has areas, such as extensions or arms, whose cross-sectional areas are separated from each other in at least one layer of powder material. In particular, it is possible that at least two component cross-sections are assigned to the same first component (DS16761P4439DE0 4 29.10.2024), while at the same time at least one further component cross-section is assigned to at least one other, second component.

[0021] The component cross-sections can be determined, which means, in particular, that determining the component cross-sections is part of the planning process. In one embodiment, the component cross-sections are determined by decomposing geometries of the components to be manufactured, 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 components 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 objects to be manufactured are 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.

[0022] However, the component cross-sections can also be provided; in this case, the determination of the component cross-sections is not part of the planning process itself, but the component cross-sections are generated in a process step preceding the planning process described here and are merely obtained or received for the planning process.

[0023] In the context of this technical teaching, the optimization of at least one optimization goal is understood to mean, in particular, that the assignment of the component cross-sections to the energy beams is carried out—optionally iteratively—in such a way that the at least one optimization goal is fulfilled as far as possible. The at least one optimization goal does not necessarily have to be fully fulfilled in the result. However, it is also not impossible that the at least one optimization goal will be fully achieved.

[0024] In the context of this technical teaching, assigning the component cross-sections to the energy beams means, in particular, that the component cross-sections are distributed among the energy beams. It is thus advantageously determined which component cross-section in the at least one planning powder material layer is irradiated by which energy beam—or, if applicable, which energy beams. DS16761P4439DE0 5 29.10.2024

[0025] In the context of this technical teaching, the optimization goal of a uniform cross-sectional distribution of the component cross-sections onto the energy beams is understood in particular to mean that the total number of component cross-sections is distributed as equally as possible among the total number of energy beams, so that as a result, each energy beam irradiates as many component cross-sections as possible.

[0026] In the context of this technical teaching, the optimization goal of a uniform distribution of the total area to be irradiated in the planning powder material layer across the energy beams is understood in particular to mean that the total area to be irradiated, i.e., the sum of the areas of all component cross-sections to be irradiated, is distributed as equally as possible among the total number of energy beams, so that, as a result, each energy beam within the planning powder material layer irradiates the same total area – that is, when all areas irradiated by the respective energy beam are added together.

[0027] In the context of this technical teaching, the optimization goal of a uniform volume distribution of the total powder volume to be solidified in the planning powder material layer across the energy beams is understood in particular to mean that the total powder volume to be solidified, i.e., the sum of the powder volumes to be solidified of all component cross-sections to be irradiated, is distributed as equally as possible across the total number of energy beams, so that, as a result, each energy beam within the planning powder material layer solidifies the same total powder volume in total – that is, when all powder volumes solidified by the respective energy beam are added together.The powder volume to be solidified can be determined in particular from the layer height of the planning powder material layer and a comparison of the respective component cross-sectional geometries assigned to each other in the planning powder material layer and the powder material layer immediately below it, i.e., immediately irradiated or intended for irradiation.

[0028] In the context of this technical teaching, the optimization goal of a uniform temporal distribution of activity time across the energy beams is understood to mean, in particular, that the total activity time—that is, the sum of all activity times of all energy beams—is distributed as equally as possible among the total number of energy beams, so that, as a result, each energy beam in the planning powder material layer has as much activity time as possible. DS16761P4439DE0 6 29.10.2024

[0029] Activity time refers specifically to the irradiation time or working time of an energy beam. Irradiation time encompasses only the time spent on actual irradiation, while working time, in contrast, also includes jumps or other shifts in a hypothetical impact position of the energy beam on the work area, during which no irradiation occurs because the energy beam is, for example, blocked or switched off.

[0030] In the context of this technical teaching, the optimization goal of a uniform vector length distribution of irradiation vectors across the energy beams is understood in particular to mean that a total vector length, i.e., the sum of all vector lengths of all irradiation vectors in the planning powder material layer, is distributed as equally as possible across the total number of energy beams, so that, as a result, each energy beam within the planning powder material layer irradiates the same total vector length in total – that is, when one adds up all vector lengths of all irradiation vectors irradiated by the respective energy beam.

[0031] An irradiation vector is understood to be, in particular, a continuous, preferably linear, displacement of an 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.

[0032] In the context of this technical teaching, the irradiation – or synonymous processing – of an irradiation vector is understood in particular to mean that a scanner device is controlled and / or the respective energy beam is actually moved within the working area in accordance with a definition given by the irradiation vector.

[0033] Each of the optimization goals listed here, but in particular a combination of at least two of the optimization goals mentioned, advantageously leads to at least a more uniform or preferably uniform utilization of the energy beams and DS16761P4439DE0 7 29.10.2024 thus to a reduced, preferably optimized, i.e. in particular minimized process time.

[0034] 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.

[0035] 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.

[0036] 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.

[0037] Especially with smaller manufacturing devices, each energy beam can typically operate across the entire working area. However, particularly with larger manufacturing devices, it may be the case that individual energy beams cannot cover the entire working area, especially if different sections of the working area are assigned to different energy beams. In one embodiment of the method, this is advantageously addressed by assigning only those energy beams to the component cross-sections located in the respective sections of the working area that are also assigned to those sections.

[0038] According to a further development of the invention, it is provided that at least one additional planning objective is taken into account when assigning the component cross-sections to the energy beams. This at least one planning objective is selected from a group consisting of irradiating the individual component cross-sections with exactly one energy beam, irradiating the individual components of a plurality of components with exactly one energy beam, avoiding soot influence zones, and a combination of at least two of the aforementioned planning objectives. Advantageously, further optimization aspects or restrictions can be considered by taking the at least one planning objective into account.

[0039] If more than one planning objective is applied, the planning objectives are given preferential weight and thus prioritized relative to each other.

[0040] Preferably, the applied optimization and planning objectives are weighted and thus prioritized relative to each other.

[0041] In the context of this technical teaching, taking into account at least one planning objective, it is understood in particular that the assignment of the component cross-sections to the energy beams – optionally iteratively – is carried out in such a way that the at least one planning objective is fulfilled as far as possible. The at least one planning objective does not necessarily have to be fully fulfilled in the result. However, it is also not impossible that the at least one planning objective will be fully achieved.

[0042] In the context of this technical teaching, the planning objective of irradiating each component cross-section with exactly one energy beam is understood to mean, in particular, that each component cross-section in the planning powder material layer is irradiated by only one energy beam, if possible. Preferably, the number of component cross-sections in the planning powder material layer that are irradiated with more than one energy beam is minimized. This proves particularly advantageous with regard to certified components, since interfaces typically arise in component areas where different energy beams cooperate or intersect, and these interfaces may have different physical properties than component areas outside these interfaces.Therefore, such seams should be avoided if possible, or their exact position and location should be known and reproducible so that no unforeseen component properties result.

[0043] In the context of this technical teaching, the planning objective of irradiating individual components of a plurality of components with exactly one energy beam is understood to mean, in particular, that each component in the planning powder material layer—and preferably also in all powder material layers—is irradiated, if possible, by only exactly one energy beam, or by as few energy beams as possible. Preferably, the number of components in the planning powder material layer—and preferably also in all powder material layers—that are irradiated with more than one energy beam is minimized. Alternatively or additionally, the total number of energy beams used per component, i.e., across all powder material layers, is minimized.

[0044] In the context of this technical teaching, the planning objective of avoiding soot-affected zones is understood to mean, in particular, that the allocation is carried out in such a way that, when using a protective gas flow with a defined flow direction over the working area, it is avoided, as far as possible, that one energy beam operates in the soot-affected zone of another energy beam. This is because such an occurrence can reduce the quality of the resulting components in two ways: firstly, through uncontrolled changes in the properties of the energy beam caused by the soot cloud, and secondly, through particles – such as splashes or smoke particles – that are carried by the protective gas flow from an area currently being irradiated to an area irradiated later.

[0045] According to a further development of the invention, a temporal sequence for irradiating the component cross-sections is determined, taking into account at least one design objective. This advantageously ensures high component quality. This applies particularly to the design objective of avoiding soot-affected zones, whereby in this case, preferably with regard to the shielding gas flow, component cross-sections upstream are irradiated after downstream component cross-sections; that is, component cross-sections that are geometrically farther from a source of the shielding gas flow are irradiated first, and those that are further away are irradiated later. DS16761P4439DE0 10 29.10.2024

[0046] Component cross-sections that are geometrically closer to the source of the shielding gas flow. In this way, it can advantageously be avoided that sections of the working area are irradiated where particles carried by the shielding gas flow are located on unsolidified powder material. At the same time, it can be avoided that an energy beam operates downstream of another energy beam in its soot-affected zone.

[0047] In one embodiment, the temporal sequence is determined according to the assignment of the component cross-sections to the energy beams. This particularly realizes the advantages already described.

[0048] In one embodiment, the irradiation parameters are determined – temporally – after the component cross-sections have been assigned to the energy beams, and preferably also – temporally – after the temporal sequence of irradiation of the component cross-sections has been established. Advantageously, the assignment – ​​and optionally the temporal sequence – 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 – and in close proximity to each other – so the irradiation parameters are sensibly adjusted accordingly, in order to prevent, in particular, overheating or cooling of certain zones of the resulting components.

[0049] 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 a beam diameter, of the energy beam on the planning powder material layer, and a combination of at least two of the aforementioned irradiation parameters.

[0050] 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 DS16761P4439DE0 11 29.10.2024

[0051] Within the process, the powder material layer is treated as a planning powder material layer. Depending on the specific implementation of the planning process on a computer device, this can occur successively, one after the other, or at least partially simultaneously. Irradiation optimization can also involve cyclical or iterative treatment of the powder material layers as planning powder material layers within the process.

[0052] By assigning the component cross-sections to the energy beams at the level of the individual powder material layers, the height and / or volume of the components to be manufactured is implicitly taken into account. The advantages already explained are particularly evident in situations where different components with varying heights and / or volumes are manufactured side-by-side within a single process.

[0053] 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 at least one component – ​​preferably a plurality of components – 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 previously described embodiments for the locally selective irradiation of a working area with a plurality of energy beams, in order to produce the at least one component layer by layer from a plurality of powder material layers arranged successively in a layer sequence in the working area, and manufacturing the at least one component according to the irradiation plan.In connection with the manufacturing process, the advantages that have already been explained in connection with the planning process become particularly apparent.

[0054] 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 previously described embodiments. Thus, the manufacturing process also includes the planning method – particularly in the form of steps preceding the actual manufacturing.

[0055] Laser beams or electron beams are preferably used as the energy beams. DS16761P4439DE0 12 29.10.2024

[0056] Preferably, the at least one component is manufactured using selective laser sintering and / or selective laser melting.

[0057] Preferably, a metallic or ceramic powder can be used as the powder material.

[0058] 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 have already been explained in connection with the planning method or the manufacturing method become particularly apparent.

[0059] 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.

[0060] The problem is also solved in a fourth aspect, in particular, by providing a planning device for planning a locally selective irradiation of a work area with a plurality of energy beams in order to produce at least one component—preferably a plurality of components—from a powder material arranged in the work area using the energy beams. 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 previously described embodiments. In connection with the planning device, the advantages are particularly evident that have already been explained in connection with the planning method, the manufacturing method, the computer program, or the storage medium. DS16761P4439DE0 13 29.10.2024

[0061] 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 one 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.

[0062] 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 instructions, in particular an NC program, for controlling the manufacturing device, wherein this sequence of instructions 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, it is possible that CAD data of a component to be manufactured is transferred to the manufacturing device, whereby the manufacturing device itself, in particular the planning device implemented in the control device, generates corresponding CAM data or a command sequence for controlling the manufacturing device from the CAD data. It is also possible, however, that the planning device comprises a plurality of computing devices, in particular being 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 so-called cloud, or the planning device is part of a data cloud or cloud. In a preferred embodiment, it is also possible that the planning device includes at least one [unclear - possibly referring to DS16761P4439DE0 14 29.10.2024].

[0063] The planning device comprises an external computing device and, on the other hand, the manufacturing device itself, in particular its control device, wherein steps performed by the planning device are carried out partly on the external computing device and partly on the manufacturing device, in particular on its control device. In particular, it is also possible that the planning device does not undertake the complete planning of the locally selective irradiation of the work area, but only parts thereof; in particular, it is possible that the planning device undertakes only that part of the planning of the locally selective irradiation of the work area which relates to the steps and / or specifications described above.Other parts of the planning for locally selective irradiation, however, can 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.

[0064] In a fifth aspect, the task is also solved in particular by creating a manufacturing device for the additive manufacturing of components from a powder material, with

[0065] - at least one beam-generating device designed to generate a plurality of energy beams,

[0066] - at least one scanner device configured to selectively irradiate a work area with energy beams in order to produce at least one component from the powder material arranged in the work area using the energy beams, and with

[0067] - a control device that is operatively connected to and configured with the at least one scanner device to control the at least one scanner device, wherein

[0068] - the control device is set up to carry out a manufacturing process according to the invention or a manufacturing process according to one or more of the previously described embodiments.

[0069] In connection with the manufacturing device, the advantages are particularly those previously explained in connection with the planning process, the manufacturing process, the computer program, the storage medium, or the planning device. DS16761P4439DE0 15 29.10.2024

[0070] In one embodiment, the beam generation device is configured to generate the plurality of energy beams, and / or the manufacturing device comprises a plurality of beam generation devices for generating the plurality of energy beams. It is possible that a plurality of scanner devices are provided for the plurality of energy beams. However, it is also possible that the scanner device is configured to relocate the plurality of energy beams—particularly independently of one another—within the work area. In particular, the scanner device can, for this purpose, comprise a plurality of separately controllable scanners, especially scanner mirrors.

[0071] 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.

[0072] A work head or processing head that can be moved relative to the working 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 working 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.

[0073] 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.

[0074] The control device can itself be designed as the planning device or can include the planning device.

[0075] 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.

[0076] 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.

[0077] According to a further development of the invention, the manufacturing device has a protective gas device which is set up to generate a protective gas flow with a defined flow direction over the working area.

[0078] The invention will be explained in more detail below with reference to the drawing. The drawing shows:

[0079] Figure 1 shows a schematic representation of an embodiment of a manufacturing device with a planning device;

[0080] Figure 2 shows 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 state of the art;

[0081] Figure 3 shows a first schematic representation of an implementation example of the planning procedure;

[0082] Figure 4A shows a second schematic representation of a first variant of the implementation example of the planning procedure;

[0083] Figure 4B shows a third schematic representation of a second variant of the implementation example of the planning procedure;

[0084] Figure 5 shows a fourth schematic representation of the implementation example of the

[0085] planning process, and

[0086] Figure 6 shows a fifth schematic representation of the implementation example of the

[0087] Planning process.

[0088] Fig. 1 shows a schematic representation of an embodiment of a

[0089] Manufacturing device 1 for the additive manufacturing of components 13 from a powder material 2 with a planning device 3. DS16761P4439DE0 17 29.10.2024

[0090] 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 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 at least one component 13, here a first component 13.1 and a second component 13.2, from the powder material 2 arranged in the working area 11 by means of the energy beams 7.Furthermore, the manufacturing device 1 includes a control device 15, which is operatively connected to and configured with the scanner devices 9 to control the scanner devices 9. The control device 15 is also preferably operatively connected to and configured with the beam generating devices 5 to control the beam generating devices 5, in particular to switch the energy beams 7 on and off and / or temporarily block them out. The control device 15 is configured to carry out a manufacturing process described in more detail below. In particular, the control device 15 includes the planning device 3 or is itself configured as the planning device 3.

[0091] The manufacturing device 1 preferably has a protective gas device 17 which is set up to generate a protective gas flow with a defined flow direction, schematically represented by arrows P, over the working area 11.

[0092] Fig. 2 shows 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 7 according to the state of the art.

[0093] Identical and functionally equivalent elements are marked with the same reference symbols in all figures, thus referring back to the preceding description. Furthermore, identical elements that appear multiple times are marked with the corresponding reference symbol only once for clarity.

[0094] According to the conventional procedure shown, the working area 11 is divided into two halves in advance - and generally for all powder material layers 21 to be irradiated sequentially one after the other - whereby the half shown here on the left is assigned to the first energy beam 7.1 - DS16761P4439DE0 18 29.10.2024 here marked with I - and whereby the half shown here on the right is assigned to the second energy beam 7.2 - here marked with II -.

[0095] Figure 2 schematically illustrates a situation in which component cross-sections 19 to be irradiated are present only in the left half, while no component cross-section to be irradiated is arranged in the right half. Such a situation can occur, for example, if components or component sections 19 are arranged in the left half that are taller, i.e., extend towards higher or—in other words—successively later powder material layers 21, than in the right half.

[0096] The blanket assignment of the two halves of the working area 11 to the energy beams 7 now leads to the situation that in the powder material layer 21 shown in Figure 2, only the first energy beam 7.1 is active, while the second energy beam 7.2 is inactive. This is uneconomical and inefficient both with regard to the utilization of the energy beams 7 and with regard to the process time.

[0097] Fig. 3 shows a first schematic representation of an implementation example of the planning procedure.

[0098] Within the framework of the planning procedure proposed here, a plurality of component cross-sections 19 of at least one component 13 to be manufactured - optionally several components 13 - are determined or provided in at least one planning powder material layer 21 ' a plurality of powder material layers 21, wherein the component cross-sections 19 are assigned to the - individual - energy beams 7.1, 7.2 of the plurality of energy beams 7 under optimization of at least one optimization goal.The at least one optimization goal is selected from a group consisting of a uniform cross-sectional distribution of the component cross-sections 19 across the energy beams 7, a uniform area distribution of a total area to be irradiated in the planning powder material layer 21' across the energy beams 7, a uniform volume distribution of a total powder volume to be solidified in the planning powder material layer 21' across the energy beams 7, a uniform temporal distribution of an activity time in the planning powder material layer 21' across the energy beams 7, a uniform vector length distribution of irradiation vectors in the planning powder material layer 21' across the energy beams 7, and a combination of at least two of the aforementioned optimization goals. DS16761P4439DE0 19 29.10.2024.

[0099] Preferably, as a result or product of the planning procedure, an irradiation plan for the locally selective irradiation of the work area 11 with the energy beams 7 in the at least one planning powder material layer 21' is obtained.

[0100] Figure 3 depicts a situation in which component cross-sections 19 are arranged across the entire working area 11. If, for example, a uniform surface distribution is used as the optimization goal, this can lead—as shown—to the same result as obtained using the conventional division: a division of the working area 11 into a left half, which is assigned to the first energy beam 7.1 (I), and a right half, which is assigned to the second energy beam 7.2 (II). However, as will be shown below, this division is not a general, predetermined division for all powder material layers 21, but rather results from the specific arrangement of the component cross-sections 19 on the working area 11 and the optimization goal used.Thus, Figure 3 makes it clear that the optimization carried out according to the invention may, under certain circumstances, yield the same result as is generally obtained in the prior art, but in a different way and only for certain powder material layers 21 under certain conditions.

[0101] Preferably, the method is carried out for a plurality of planning powder material layers 21 ', particularly preferably for all powder material layers 21 as planning powder material layers 21 ' .

[0102] Fig. 4 A shows a second schematic representation of a first variant of the exemplary embodiment of the planning procedure.

[0103] Here is the initial situation shown in Figure 2, in which only component cross-sections 19 in the left half of the working area 11 are to be irradiated, while the right half is free of surfaces to be irradiated.

[0104] The advantageous optimization of an optimization goal for the allocation of the energy beams 7 to the component cross-sections 19 - whereby the uniform area distribution is again used as the optimization goal - now leads to the fact that the component cross-sections 19 are divided at least approximately halfway between the energy beams 7 with respect to their total area.

[0105] In particular, if no further planning objective is taken into account according to the first variant shown here, this can lead – as shown – to component cross-sections 19 being divided into influence zones of the different energy beams 7; thus, a left area DS16761P4439DE0 20 29.10.2024 of the component cross-sections 19 is assigned to the first energy beam 7.1 (I), while a right area of ​​the component cross-sections 19 is assigned to the second energy beam 7.2 (II), with a dividing line extending vertically in the figure dividing the three right component cross-sections 19.

[0106] Because, in contrast to the procedure according to Figure 2, the component cross-sections 19 are processed by both energy beams 7, an improved utilization of the energy beams 7 and a reduced process time result.

[0107] Fig. 4B shows a third schematic representation of a second variant of the implementation example of the planning procedure.

[0108] When assigning the component cross-sections 19 to the energy beams 7, at least one additional planning objective is preferably taken into account, wherein the at least one planning objective is selected from a group consisting of irradiating the individual component cross-sections 19 with exactly one energy beam 7, irradiating the individual components 13 or a plurality of components 13 with exactly one energy beam 7, avoiding soot influence zones, and a combination of at least two of the aforementioned planning objectives.

[0109] In the second variant presented here, the optimization goal is again a uniform surface distribution, and the planning goal is specifically to ensure that each component cross-section 19 is irradiated with exactly one energy beam 7, preferably minimizing the number of component cross-sections 19 irradiated with more than one energy beam 7. Consequently, the distribution—in contrast to the distribution according to the first variant shown in Figure 4A—is such that the three leftmost round component cross-sections 19, shown vertically one above the other in the figure, and additionally an upper part of the uppermost rectangular component cross-section 19 in the figure are assigned to the first energy beam 7.1 (I), while a lower part of the uppermost rectangular component cross-section 19 and the two rectangular component cross-sections 19 shown vertically below it are assigned to the second energy beam 7.2 (II).Thus, only one component cross-section 19 is divided between the energy beams 7.

[0110] Of course, the division could also be carried out in such a way that no component cross-section 19 is divided between the energy beams 7. However, this conflicts with the optimization goal of a uniform surface distribution. DS16761P4439DE0 21 29.10.2024

[0111] The optimization and planning objectives applied are preferably weighted and thus prioritized relative to each other. The result shown here can be obtained, for example, if the optimization objective of uniform surface distribution is weighted more highly than the planning objective of irradiating the individual component cross-sections 19 with exactly one energy beam 7.

[0112] In the variant shown, a temporal sequence for the irradiation of the component cross-sections is also defined, taking into account at least one planning objective.

[0113] For this purpose, the planning objective of avoiding a soot influence zone is specifically applied. To clarify, arrow P is shown again, indicating the direction of flow of the protective gas over the working area 11. The temporal sequence of the irradiation is advantageously chosen such that the first energy beam 7.1 preferably irradiates its assigned part of the upper right component cross-section 19 in the figure, while the second energy beam 7.2 is inactive. When the first energy beam 7.1 then begins to irradiate the round component cross-sections 19 on the left in the figure, the second energy beam 7.1 irradiates its assigned part of the upper right component cross-section 19 as well as the rectangular component cross-sections 19 located below it. In both cases, the irradiation preferably occurs against the flow direction. This approach advantageously avoids the first energy beam 7.1 irradiating the upper right component cross-section 19, as well as the rectangular component cross-sections 19 located below it.1. in a soot-affected zone of the second energy beam 7.2, and secondly, the introduction of particles into areas of the powder material layer 21 that have not yet been irradiated is avoided.

[0114] The fact that this results in an inactivity period for the second energy beam 7.2 in the specific example shown can be taken into account when allocating the area, for example, by ensuring that both energy beams 7 finish irradiating the powder material layer 21 at approximately the same time. The corresponding assignment of the component cross-sections 19 to the energy beams 7, as well as the determination of the temporal sequence, can be iteratively adjusted and optimized.

[0115] Preferably, irradiation parameters are determined – temporally – after the component cross-sections 19 have been assigned to the energy beams 7, and preferably also after the temporal sequence of irradiation of the component cross-sections 19 has been determined. At least one irradiation parameter is preferably selected from a group consisting of a line energy, a displacement velocity of a DS16761P4439DE0 22 29.10.2024

[0116] Energy beam 7 along an irradiation vector, a beam shape of the energy beam 7 on the planning powder material layer 21 ', a beam size, in particular beam diameter, of the energy beam 7 on the planning powder material layer 21 ', and a combination of at least two of the aforementioned irradiation parameters.

[0117] Fig. 5 shows a fourth schematic representation of the exemplary embodiment of the planning procedure.

[0118] In comparison to Figures 4A and 4B, a higher, or in other words, a later, successively applied layer of planning powder material 21' is shown here, in which the area of ​​the rectangular component cross-sections 19 is smaller; for example, the assigned components 13 become smaller geodesically upwards, and may, for instance, become pyramidal at least in sections. In the specific situation shown, the assignment with the optimization goal of a uniform area distribution leads to the fact that the round component cross-sections 19 shown on the left are completely assigned to the first energy beam 7.1 (I), while the rectangular component cross-sections 19 shown on the right are completely assigned to the second energy beam 7.2 (II).

[0119] Fig. 6 shows a fifth schematic representation of the exemplary embodiment of the planning procedure.

[0120] In comparison to Figure 5, an even higher, or—to put it another way—a later planning powder material layer 21' is shown, in which only the round component cross-sections 19 are present. These are thus assigned to the tallest components 13, which extend furthest geodesically upwards in the sequence of powder material layers 21. In the specific situation shown, the assignment with the optimization goal of a uniform surface distribution leads to the uppermost component cross-section 19 and half of the middle component cross-section 19 being assigned to the first energy beam 7.1 (I), while the lower half of the middle component cross-section 19 and the lowest component cross-section 19 are assigned to the second energy beam 7.2 (II).

[0121] It becomes clear that – in contrast to the conventional method according to Figure 2 – a distribution across all available energy beams 7 is preferably achieved in all powder material layers 21, particularly as uniformly as possible, so that their utilization is as homogeneous as possible and the process time is reduced. DS16761P4439DE0 23 29.10.2024

[0122] Within the framework of a manufacturing process proposed here, an irradiation plan obtained using the planning process is provided, and at least one component 13 is manufactured according to the irradiation plan.

Claims

DS16761P4439DE0 24 29.10.2024 REQUIREMENTS 1. Method for planning a locally selective irradiation of a work area (11) with a plurality of energy beams (7) in order to produce at least one component (13) layer by layer from a plurality of powder material layers (21) of a powder material (2) arranged in a layer sequence in the work area (11) by means of the energy beams (7), wherein - in at least one planning powder material layer (21') of the plurality of powder material layers (21) a plurality of component cross-sections (19) of at least one component (13) to be manufactured is determined or provided, wherein - the component cross-sections (19) are assigned to the energy beams (7) of the majority of energy beams (7) under optimization of at least one optimization goal, wherein - that at least one optimization goal is selected from a group consisting of a uniform cross-sectional distribution of the component cross-sections (19) onto the energy beams (7), a uniform area distribution of a total area to be irradiated in the planning powder material layer (21') onto the energy beams (7), a uniform volume distribution of a total powder volume to be solidified in the planning powder material layer (21') onto the energy beams (7), a uniform temporal distribution of an activity time onto the energy beams (7), a uniform vector length distribution of irradiation vectors onto the energy beams (7), and a combination of at least two of the aforementioned optimization goals, and wherein in particular - an irradiation plan for the locally selective irradiation of the work area (11) with the energy beams (7) in which at least one planning powder material layer (21') is obtained.

2. Method according to claim 1, wherein, in assigning the component cross-sections (19) to the energy beams (7), at least one additional planning objective is taken into account, wherein the at least one planning objective is selected from a group consisting of irradiation of the individual component cross-sections (19) with exactly one energy beam (7), irradiation of the individual components (13) of a plurality of components (13) with exactly one energy beam (7), avoidance of soot influence zones, and a combination of at least two of the aforementioned planning objectives. DS16761P4439DE0 25 29.10.2024 3. Method according to one of the preceding claims, wherein a temporal sequence of irradiation of the component cross-sections (19) is determined taking into account the at least one planning objective, in particular according to the assignment of the component cross-sections (19) to the energy beams (7).

4. Method according to one of the preceding claims, wherein the method is carried out for a plurality of planning powder material layers (21'), preferably for all powder material layers (21) of the plurality of powder material layers (21).

5. Method for additively manufacturing at least one component (13) 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 4 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 (13) layer by layer from a plurality of powder material layers (21) 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 (13) according to the irradiation plan.

6. 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 5.

7. 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 (13) 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 4.

8. Manufacturing device (1) for additive manufacturing of components (13) 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 selectively irradiate a work area (11) with the energy beams (7) in order to use the DS16761P4439DE0 26 29.10.2024 energy beams (7) to produce at least one component (13) from the powder material (2) arranged in the work area (11), and with - a control device (15) which is operatively connected to and configured with the at least one scanner device (9) to control the at least one scanner device (9), wherein - the control device (15) is configured to carry out a method according to claim 5.

9. Manufacturing device (1) according to claim 8, comprising a protective gas device (17) which is configured to generate a protective gas flow with a defined flow direction over the working area (11).

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