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WO2026008387A1 - Procédé d'essai d'un dispositif de fabrication, et dispositif de commande et dispositif de fabrication pour la fabrication additive de composants à partir d'un matériau en poudre - Google Patents

Procédé d'essai d'un dispositif de fabrication, et dispositif de commande et dispositif de fabrication pour la fabrication additive de composants à partir d'un matériau en poudre

Info

Publication number
WO2026008387A1
WO2026008387A1 PCT/EP2025/067649 EP2025067649W WO2026008387A1 WO 2026008387 A1 WO2026008387 A1 WO 2026008387A1 EP 2025067649 W EP2025067649 W EP 2025067649W WO 2026008387 A1 WO2026008387 A1 WO 2026008387A1
Authority
WO
WIPO (PCT)
Prior art keywords
manufacturing
energy beam
area
radiation
detected
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2025/067649
Other languages
German (de)
English (en)
Inventor
Bernhard Gutmann
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Trumpf Laser und Systemtechnik Se
Original Assignee
Trumpf Laser und Systemtechnik Se
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Trumpf Laser und Systemtechnik Se filed Critical Trumpf Laser und Systemtechnik Se
Publication of WO2026008387A1 publication Critical patent/WO2026008387A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/31—Calibration of process steps or apparatus settings, e.g. before or during manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/80—Data acquisition or data processing
    • B22F10/85—Data acquisition or data processing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/90—Means for process control, e.g. cameras or sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2203/00—Controlling
    • B22F2203/03—Controlling for feed-back

Definitions

  • the invention relates to a method for testing a manufacturing device, a control device for carrying out such a method and a manufacturing device for additively manufacturing components from a powder material.
  • a monitoring device can be provided in a dedicated manufacturing setup. This device detects electromagnetic radiation emitted from a melt pool during production—also known as "remitted radiation.” The manufacturing process can then be observed in real time based on the detected radiation and, if necessary, aborted if a problem is identified, particularly if it can be determined that the component currently being manufactured must be rejected. In this way, rejects can be detected early, but not avoided.
  • a pre-acquired dataset for the specific manufacturing process being monitored can be used. This dataset might include, for example, signal values for the time-dependent remitted radiation that would be detected during a defect-free production run.
  • the signal values acquired during the current manufacturing process can then be compared with the dataset, and a decision can be made, based on the comparison, as to whether the manufacturing process should be continued or aborted.
  • a dataset is typically acquired once under test conditions and then used for a multitude of manufacturing processes.
  • the problem is that over time, especially with an increasing number of manufacturing processes, deviations can occur between the detected radiation and the signal values stored in the data set, which These deviations are not caused by problems or errors in the manufacturing process, but can have various other causes, particularly within the manufacturing equipment itself, such as deposits on optics or similar components.
  • the invention is therefore based on the objective of creating a method for testing a manufacturing device, a control device for carrying out such a method and a manufacturing device for the additive manufacturing of components from a powder material, wherein the aforementioned disadvantages are at least reduced, preferably avoided.
  • the problem is solved, in particular, by creating a method for testing a manufacturing device for the additive manufacturing of components from a powder material.
  • This method involves irradiating a predetermined test area with at least one energy beam, recording the radiation reflected from the test area by at least one monitoring device, and evaluating the manufacturing device based on the recorded reflected radiation.
  • This advantageously allows the manufacturing device to be evaluated before the actual manufacturing process and any problems to be identified early on, thus preventing potential rejects from being produced during the actual manufacturing process. If necessary, a suitable measure can then be taken to rectify any identified problem. This helps to avoid rejects, thereby reducing overall manufacturing time and costs.
  • the method simultaneously enables an evaluation of the monitoring device itself and thus an assessment of whether signal values recorded during a subsequent manufacturing process can be meaningfully compared with a previously acquired data set to determine the The manufacturing process is evaluated. If necessary, a suitable measure can then be taken to ensure comparability of the recorded signal values with the data set, for example, by cleaning optics or scaling the recorded values. This can advantageously prevent unnecessary interruptions to the manufacturing process, thereby also reducing manufacturing time and costs.
  • the monitoring device is a melt pool monitoring device, which is set up to monitor a melt pool of powder material melted by the at least one energy beam during the manufacture of a component.
  • remitted radiation refers specifically to electromagnetic radiation emitted from the test surface, particularly reflected and/or scattered or thermally emitted.
  • “reflection” is understood in the narrower sense to mean specular or directional reflection, while “scattering” refers to diffuse reflection, especially according to Lambert's law.
  • the remitted radiation can be any type of thermal radiation, scattering, or luminescence, including, in particular, fluorescence, phosphorescence, Lambert scattering, Mie scattering, multiphoton scattering, or Raman scattering.
  • the test area is arranged in particular in a working area of the manufacturing device in which the powder material is arranged in order to produce at least one component from the powder material arranged in the working area by means of at least one energy beam generated by the manufacturing device for this purpose.
  • a predetermined test surface with known optical properties is used. This allows the properties of the test surface to be taken into account or subtracted, if necessary, so that only the manufacturing device, and not a combination of the manufacturing device and the test surface, is evaluated based on the measured reflected radiation.
  • the test surface has homogeneous, and in particular constant, optical properties across its entire extent.
  • a substrate plate of the manufacturing device – in particular an uncoated one – is used as the predetermined test surface.
  • "Uncoated” means... It is understood that no powder material has yet been arranged on the substrate plate.
  • such an uncoated substrate plate can have very precisely known, especially optical, properties.
  • an unmelted layer of powder material is used, in particular a layer of powder material arranged directly on the substrate plate or the topmost layer of a small number of powder material layers arranged directly on the substrate plate.
  • the small number of powder material layers arranged directly on the substrate plate can be, in particular, two to ten, in particular three to five, and in particular four.
  • the method can be carried out, in particular, initially before a manufacturing process in order to test the manufacturing device.
  • a user of the manufacturing device can manually select and/or start the method as needed in a control system of the manufacturing device.
  • the method can also be carried out during a manufacturing process if required.
  • the manufacturing process can be interrupted by a user to initiate the method.
  • the emitted radiation is detected by a monitoring device associated with an energy beam of the manufacturing device.
  • the emitted radiation is detected along an optical axis of the associated energy beam by arranging a measuring device, configured to detect the emitted radiation, on the optical axis.
  • a scanner device configured to relocate the associated energy beam includes a deflecting mirror by which the associated energy beam is deflected, wherein the reflectivity of the deflecting mirror—particularly in a wavelength range of the reflected radiation that may differ from a wavelength of the associated energy beam—is less than 100%, such that at least a portion of the radiation reflected along the optical axis passes through the deflecting mirror and falls onto the measuring device arranged behind the deflecting mirror.
  • the associated energy beam it is also possible for the associated energy beam to be sent through the deflecting mirror, wherein the The measuring device is then arranged in such a way that the remitted radiation is partially deflected by the deflecting mirror and directed to the measuring device.
  • the associated energy beam passes through an opening in a deflecting mirror, wherein the remitted radiation is at least partially deflected by the surface of the deflecting mirror surrounding the opening and directed to the measuring device.
  • a so-called scraper mirror can be used.
  • a polarization beam splitter can be used instead of the deflecting mirror, in which case the associated energy beam is preferably linearly polarized.
  • the polarization is at least partially destroyed, with the polarization direction perpendicular to the incident energy beam then containing only the signal of the remitted radiation.
  • the polarization beam splitter thus preferentially reflects the incident radiation of the associated energy beam, which is linearly polarized with a specific polarization direction, and transmits the polarization direction perpendicular to that specific polarization direction – or vice versa.
  • the manufacturing device is preferably configured for selective laser sintering. Alternatively or additionally, the manufacturing device is configured for selective laser melting.
  • Additive or generative manufacturing of a component is understood to mean, in particular, a powder bed-based process for manufacturing a component, specifically 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).
  • LMF laser metal fusion
  • DMLM direct metal laser melting
  • LNSM laser net shaping manufacturing
  • SEBM selective electron beam melting
  • LENS laser engineered net shaping
  • the powder material is a pure powder or a powder mixture.
  • a metallic or ceramic powder can be used as the powder material.
  • the metallic powder material can be in the form of a pure metal powder or a metal alloy powder, for example, a steel, aluminum, or titanium alloy.
  • the at least one energy beam is generated by a beam generation device of the manufacturing apparatus.
  • an energy beam already present in the manufacturing process can be used in the test procedure in this way; furthermore, this approach also allows the energy beam itself, in particular its beam path, optical components in the beam path, and the beam generation device to be tested.
  • the at least one energy beam is selected, in particular, 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.
  • the at least one energy beam can be continuous or pulsed, in particular continuous laser radiation or pulsed laser radiation.
  • At least one energy beam is generated by at least one radiation-generating device.
  • the at least one radiation-generating device is designed as a laser.
  • the energy beams are thus advantageously generated as intense beams of coherent electromagnetic radiation, in particular coherent light. Irradiation in this context preferably means exposure.
  • the remitted radiation is detected by a monitoring device, in particular a melt pool monitoring device, assigned to the at least one energy beam of the manufacturing device intended for production.
  • the monitoring device used can be precisely the same one assigned to the energy beam used for the test procedure.
  • a monitoring device assigned to a different energy beam or a plurality of energy beams of the manufacturing device intended for production can be used.
  • an energy beam in particular an energy beam provided separately for the testing procedure, especially a pilot or auxiliary beam
  • This energy beam is also preferably a laser beam. It can be generated by a beam source associated with the manufacturing device or by a beam source provided separately from the manufacturing device.
  • an exposure laser such as for example, can be used as the beam source for the pilot or auxiliary beam.
  • High-speed recordings, or in a particularly simple way, a laser pointer can be used.
  • the at least one monitoring device is evaluated based on the detected remitted radiation.
  • this method ensures, in particular, that the observation and evaluation of a manufacturing process is carried out correctly, thereby avoiding false positive detection of rejects.
  • the beam path of at least one energy beam – particularly one intended for manufacturing – is evaluated based on the detected remitted radiation. This ensures, in particular, the correct emission of the at least one energy beam, thus preventing the generation of defective parts.
  • an optical component for the at least one energy beam – intended particularly for manufacturing – is evaluated based on the detected remitted radiation. This also advantageously contributes both to avoiding rejects through correct emission of the energy beam and to correct monitoring and evaluation of the manufacturing process.
  • the optical component can be, in particular, an optical element that influences the energy beam, especially beam-shaping or deflecting optics, for example a lens, a prism or a mirror, a window or a protective glass.
  • beam-shaping or deflecting optics for example a lens, a prism or a mirror, a window or a protective glass.
  • the at least one beam-generating device is evaluated based on the detected remitted radiation.
  • this ensures that the at least one energy beam – particularly intended for manufacturing – is generated correctly and, in particular, with the correct power, thereby avoiding rejects and ensuring accurate monitoring and evaluation of the manufacturing process.
  • the at least one energy beam is moved along a predetermined beam path across the predetermined test area, with the remitted radiation being detected along the predetermined beam path.
  • a larger area of the manufacturing device can be evaluated in this way – particularly locally. during this transfer, at least one energy beam not only passes over different areas of the test surface, but also over different areas of optical components, which may be locally contaminated or damaged.
  • the manufacturing device is therefore locally evaluated based on the remitted radiation detected along the predetermined beam path.
  • the emitted radiation is detected point-wise, particularly one-dimensionally, or in a small number of pixels, particularly fewer than ten, particularly fewer than five, and especially location-dependently.
  • Each location of a displacement of the energy beam is thus preferably assigned exactly one signal value or at least a small number of signal values.
  • a signal value is, in particular, a brightness value or intensity value.
  • the test surface is irradiated with a plurality of energy beams.
  • several energy beams in particular several energy beams of the manufacturing device intended for production, preferably all energy beams of the manufacturing device, can be used for evaluation or evaluated independently of one another or in combination with one another.
  • the remitted radiation associated with each energy beam – particularly those intended for manufacturing – is detected by a monitoring device assigned to that energy beam.
  • each monitoring device detects a local area on the test surface that is irradiated by the energy beam assigned to that device. In this way, remitted radiation can be detected very precisely at the point where the at least one energy beam acts on the test surface.
  • the remitted radiation of one energy beam can be detected by a monitoring device assigned to a different energy beam.
  • the aforementioned methods can also be combined: for example, if an anomaly is detected by the monitoring device assigned to a particular energy beam, this can be checked and, if necessary, validated or verified by another monitoring device assigned to a different energy beam.
  • at least one measure is carried out depending on the evaluation of the manufacturing device. As previously explained, this advantageously avoids rejects and/or prevents a manufacturing process from being terminated due to a false positive reject detection.
  • the at least one measure is selected from a group consisting of cleaning an optical component for the at least one energy beam, calibrating the at least one beam generating device, calibrating the monitoring device, measuring the power of the at least one energy beam, deactivating the at least one beam generating device, identifying a problem area on the test surface, and a combination of at least two of the aforementioned measures.
  • Cleaning the optical component can advantageously prevent the energy beam passing through the optical component from having a suboptimal beam shape or insufficient intensity locally, and/or prevent, for example, an insufficient intensity of remitted radiation from being detected due to a locally reduced intensity of the energy beam.
  • Calibrating the beam generation device advantageously ensures that the at least one energy beam – particularly intended for manufacturing – is generated correctly, that is, specifically with the desired, predetermined parameters. This affects both the quality of the manufactured components and the detected intensity of the emitted radiation.
  • Calibrating the monitoring device can advantageously ensure that the detected intensities of the remitted radiation correspond to the expected values, in particular to the pre-generated data set, or that the detected intensities of different monitoring devices correspond to each other.
  • a sub-area of the working area of the manufacturing device associated with the problem area is removed from the production plan for manufacturing at least one component.
  • this avoids manufacturing in the sub-area of the working area associated with the problem area, thereby preventing either the scrap or false positive rejection detection that would otherwise be expected in that area.
  • Removing the corresponding sub-area from the production plan means, in particular, that the production of a component or part of a component from the corresponding sub-area is shifted to another sub-area of the working area not associated with a problem area—a so-called "good area.”
  • a measuring device arranged on a beam axis of an energy beam of the manufacturing device is used as the monitoring device. This allows, on the one hand, the advantageous use of an already existing measuring device, and on the other hand, the very precise local detection of reflected radiation at the point where the at least one energy beam acts on the test surface.
  • the measuring device can comprise at least one light-sensitive surface element, also referred to as a photosite, pixel, or sensor, a light-sensitive diode, in particular a photodiode, or another light-sensitive device.
  • the measuring device can comprise a single pixel or a collection of pixels, e.g., a pixel row or a pixel array.
  • the measuring device is selected from a group consisting of a photodiode, a quadrant sensor, a camera, and a combination of at least two of the aforementioned measuring devices.
  • a quadrant sensor is understood to be, in particular, a sensor with a plurality of photodiodes, especially four photodiodes.
  • the different photodiodes differ in their spectral sensitivity, so that emitted radiation in different wavelength ranges can be detected with the different photodiodes.
  • a camera is used as the measuring device, it is preferably a camera with a small number of pixels, in particular less than ten pixels.
  • an area camera or another sensor can be used which simultaneously captures a larger section of the work area, in particular the entire work area.
  • control device for a manufacturing device for the additive manufacturing of components from a powder material, wherein the control device is configured to carry out a method according to the invention or a method according to one or more of the embodiments described above.
  • control device In connection with the control device, the advantages that have already been explained in connection with the method are particularly evident.
  • the problem is also solved by creating a manufacturing device for the additive manufacturing of components from a powder material, which has at least one beam generation device, wherein the beam generation device is configured to generate at least one energy beam.
  • the manufacturing device also has at least one scanner device, which is configured to locally and selectively irradiate a working area with the at least one energy beam in order to produce at least one component from the powder material arranged in the working area by means of the at least one energy beam.
  • the manufacturing device has a monitoring device, which is preferably configured to monitor a melt pool of the powder material melted by the at least one energy beam during the manufacturing of a component.
  • the manufacturing device has a control device according to the invention or a control device according to one or more of the embodiments described above.
  • the monitoring device is, in particular, configured to detect radiation remitted from a test area arranged in the working area.
  • the manufacturing device additionally includes a beam source provided separately for the test procedure to generate a further energy beam, in particular a pilot or auxiliary beam.
  • this beam source is a laser, for example an exposure laser or a laser pointer.
  • the control device is specifically interconnected with the scanner device and the monitoring device.
  • the at least one scanner device preferably comprises at least one scanner, in particular a galvanometer scanner, piezo scanner, polygon scanner, MEMS scanner, and/or a 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 between a plurality of irradiation positions.
  • 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.
  • a work head can, in particular, be designed in a gantry configuration or be guided by a robot.
  • the work head can be designed as the robot hand of a robot.
  • 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.
  • 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.
  • the monitoring device has a measuring device arranged on a beam axis of the energy beam, which is designed in particular as a photodiode, quadrant sensor or camera.
  • the measuring device of the monitoring device can also be an area camera or another sensor that simultaneously captures a larger section of the work area, in particular the entire work area.
  • Figure shows a schematic representation of an embodiment of a manufacturing device for producing at least one component.
  • the single figure shows a schematic representation of an embodiment of a manufacturing device 1 for the additive manufacturing of components from a powder material.
  • the manufacturing device 1 comprises at least one beam generation device 3 configured to generate at least one energy beam 5, preferably a laser beam.
  • the manufacturing device 1 also comprises at least one scanner device 7 configured to locally and selectively irradiate a working area 9 with the at least one energy beam 5 in order to produce at least one component from the powder material arranged in the working area 7 using the at least one energy beam 5.
  • the manufacturing device 1 comprises a monitoring device 11, for example, configured as a melt pool monitoring device, which is optionally configured to monitor a melt pool of the powder material melted by the at least one energy beam 5 during the production of a component, wherein the monitoring device 11 is particularly configured to detect radiation 17 emitted from a test area 15 arranged in the working area 9.
  • the manufacturing device 1 has a control device 13 which is operatively connected and set up, in particular with the scanner device 7 and the monitoring device 11, to carry out a method for testing the manufacturing device 1 which is described in more detail below.
  • this test procedure is carried out using the at least one energy beam 5, which is also intended for manufacturing.
  • a separate energy beam for which a separate beam source, in particular a laser, for example an exposure laser or a laser pointer, can be provided.
  • the monitoring device 11 preferably comprises a measuring device 19 arranged on a beam axis A of the energy beam 5.
  • the measuring device 19 preferably comprises at least one light-sensitive surface element, also referred to as a photosite, pixel, or sensor, a light-sensitive diode, in particular a photodiode, or another light-sensitive device.
  • the measuring device 19 can be a single pixel or a
  • the measuring device 19 comprises a collection of pixels, e.g., a pixel row or a pixel array.
  • the measuring device 19 is selected from a group consisting of a photodiode, a quadrant sensor, a camera, and a combination of at least two of the aforementioned measuring devices.
  • the scanner device 7 has a deflecting mirror 21, over which the energy beam 5 is deflected, wherein the reflectivity of the deflecting mirror 21 - particularly in a wavelength range of the reflected radiation that may deviate from a wavelength of the energy beam 5 - is less than 100%, so that at least a portion of the radiation 17 reflected along the optical axis A passes through the deflecting mirror 21 and falls onto the measuring device 19 arranged behind the deflecting mirror 21, wherein the reflected radiation 17 is preferably imaged onto the measuring device 19 by an imaging optic 23, which is shown here as a single lens.
  • a predetermined test area 15 is irradiated with the energy beam 7, and the radiation 17 emitted from the test area 15 is detected by the monitoring device 11.
  • the manufacturing device 1 is evaluated based on the detected emitted radiation 17.
  • the predetermined test area 15 can be a substrate plate of the manufacturing device 1, in particular an uncoated one.
  • the predetermined test area 15 can be a layer of powder material that has not yet melted, in particular a layer of powder material arranged directly on the substrate plate or the uppermost layer of a small number of powder material layers arranged directly on the substrate plate.
  • the procedure can be performed initially before a manufacturing process to test the manufacturing device 1.
  • a user can manually select and/or start the procedure in a control system of the manufacturing device 1.
  • the test area 15 is a freshly applied layer of powder material applied during a manufacturing process – particularly over already melted powder material layers.
  • the method can also be carried out during a manufacturing process if required.
  • the manufacturing process can be interrupted by a user and the method started for this purpose.
  • the monitoring device 11 is evaluated based on the detected remitted radiation 17.
  • the beam path of the energy beam 5 is evaluated based on the detected remitted radiation 17.
  • an optical component for the energy beam 5 is evaluated based on the detected remitted radiation 17.
  • the optical component can be, in particular, an optic that influences the energy beam 5, especially beam-shaping or deflecting optics, for example a lens, a prism or a mirror, a window or a protective glass.
  • the radiation generating device 3 is evaluated based on the detected remitted radiation 17.
  • the energy beam 5 is moved along a predetermined beam path over the predetermined test area 15, with the remitted radiation being detected along the predetermined beam path.
  • the manufacturing device 1 is locally evaluated based on the remitted radiation detected along the predetermined beam path.
  • the emitted radiation 17 is detected pointwise, particularly one-dimensionally, or in a small number of pixels, particularly fewer than ten, particularly fewer than five, and especially location-dependently.
  • Each location of a displacement of the energy beam 5 is thus preferably assigned exactly one signal value or at least a small number of signal values.
  • a signal value is, in particular, a brightness value or intensity value.
  • the test area 15 is preferably irradiated with a plurality of energy beams 5.
  • the emitted radiation 17 associated with each energy beam 5 is detected by a monitoring device 11 assigned to each energy beam 5.
  • each monitoring device 11 detects a local area on the test surface 15 that is irradiated by the energy beam 5 assigned to the respective monitoring device 11.
  • remitted radiation 17 from an energy beam 5 is detected by a monitoring device 11 assigned to a different energy beam 5.
  • the aforementioned procedures can also be combined: For example, if an anomaly is detected by the monitoring device 11 assigned to a particular energy beam 5, this can be reported by a The monitoring device 11 associated with the other energy beam 5 is checked and, if necessary, validated or verified.
  • At least one measure is carried out depending on the evaluation of the manufacturing device 1.
  • This measure is preferably selected from a group consisting of cleaning an optical component for the at least one energy beam 5, calibrating the at least one beam generating device 3, calibrating the monitoring device 11, measuring the power of the at least one energy beam 5, deactivating the at least one beam generating device 3, identifying a problem area on the test surface 15, and a combination of at least two of the aforementioned measures.
  • a problem area is identified on the test area 15, a sub-area of the work area 9 of the manufacturing device 1 associated with the problem area is removed from a production plan for the manufacture of at least one component. It is preferably provided that if a problem area is identified on the test area 15, a sub-area of the work area 9 of the manufacturing device 1 associated with the problem area is removed from a production plan for the manufacture of at least one component.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Automation & Control Theory (AREA)
  • Mechanical Engineering (AREA)
  • Analytical Chemistry (AREA)
  • Plasma & Fusion (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention concerne un procédé d'essai d'un dispositif de fabrication (1) pour la fabrication additive de composants à partir d'un matériau en poudre, une surface d'essai spécifiée (15) étant exposée à au moins un faisceau d'énergie (5), le rayonnement (17) renvoyé par la surface d'essai (15) étant détecté par au moins un dispositif de surveillance (11), et le dispositif de fabrication (1) étant évalué sur la base du rayonnement (17) réémis détecté.
PCT/EP2025/067649 2024-07-01 2025-06-24 Procédé d'essai d'un dispositif de fabrication, et dispositif de commande et dispositif de fabrication pour la fabrication additive de composants à partir d'un matériau en poudre Pending WO2026008387A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102024118601.1A DE102024118601A1 (de) 2024-07-01 2024-07-01 Verfahren zum Testen einer Fertigungsvorrichtung, Steuervorrichtung und Fertigungsvorrichtung zum additiven Fertigen von Bauteilen aus einem Pulvermaterial
DE102024118601.1 2024-07-01

Publications (1)

Publication Number Publication Date
WO2026008387A1 true WO2026008387A1 (fr) 2026-01-08

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PCT/EP2025/067649 Pending WO2026008387A1 (fr) 2024-07-01 2025-06-24 Procédé d'essai d'un dispositif de fabrication, et dispositif de commande et dispositif de fabrication pour la fabrication additive de composants à partir d'un matériau en poudre

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DE (1) DE102024118601A1 (fr)
WO (1) WO2026008387A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180093416A1 (en) * 2016-09-30 2018-04-05 Eos Gmbh Electro Optical Systems Method For Calibrating A Device For Producing A Three-Dimensional Object And Device Configured For Implementing Said Method
US20210260663A1 (en) * 2018-11-12 2021-08-26 Trumpf Laser- Und Systemtechnik Gmbh Methods for detecting a working area of a generative manufacturing device and manufacturing devices for generatively manufacturing components from a powder material
EP3406373B1 (fr) * 2017-05-22 2021-12-22 nLIGHT, Inc. Commande temporelle à échelle fine pour traitement de matériau laser
EP4091742A1 (fr) * 2021-04-16 2022-11-23 Concept Laser GmbH Détection d'anomalies optiques sur des éléments optiques utilisés dans une machine de fabrication additive
US20230302538A1 (en) * 2020-07-06 2023-09-28 Renishaw Plc Improvements in or relating to an optical scanner for directing electromagnetic radiation to different locations within a scan field

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4536426A1 (fr) 2022-06-07 2025-04-16 Nikon SLM Solutions AG Procédé d'étalonnage et système d'impression conçu pour produire une pièce tridimensionnelle
US20240173920A1 (en) 2022-11-28 2024-05-30 Concept Laser Gmbh Methods and systems for calibrating an additive manufacturing machine
DE102022134779A1 (de) 2022-12-23 2024-07-04 Nikon Slm Solutions Ag Kalibrierplatte und kalibrierungstechnik

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20180093416A1 (en) * 2016-09-30 2018-04-05 Eos Gmbh Electro Optical Systems Method For Calibrating A Device For Producing A Three-Dimensional Object And Device Configured For Implementing Said Method
EP3406373B1 (fr) * 2017-05-22 2021-12-22 nLIGHT, Inc. Commande temporelle à échelle fine pour traitement de matériau laser
US20210260663A1 (en) * 2018-11-12 2021-08-26 Trumpf Laser- Und Systemtechnik Gmbh Methods for detecting a working area of a generative manufacturing device and manufacturing devices for generatively manufacturing components from a powder material
US20230302538A1 (en) * 2020-07-06 2023-09-28 Renishaw Plc Improvements in or relating to an optical scanner for directing electromagnetic radiation to different locations within a scan field
EP4091742A1 (fr) * 2021-04-16 2022-11-23 Concept Laser GmbH Détection d'anomalies optiques sur des éléments optiques utilisés dans une machine de fabrication additive

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