Method and device for producing components in a beam melting installation

• US 10,035,304 B2
• Filed: 04/10/2013
• Issued: 07/31/2018
• Est. Priority Date: 04/20/2012
• Status: Active Grant

• Current Assignee: EOS GmbH Electro Optical Systems
• Original Assignee: EOS GmbH Electro Optical Systems
• Inventors: Reinarz, Bernd
• Primary Examiner(s): Ross, Dana
• Assistant Examiner(s): MAYE, AYUB A
• Application Number:
  US14/395,284
• Publication Number:
  US 20150115490A1
• Time in Patent Office: 1,938 Days
• Field of Search: 2191216, 21912165, 21912166, 21912185
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/37 of powder bed aspects, e.g. density
• CPC Class Codes: B22F 10/85 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B22F 12/67 Blades
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

The invention relates to a beam melting installation and method for producing components thereof, in which a component to be produced is produced layer-wise, wherein, a coating slide moves across a build platform, a powder layer is applied onto the build platform and already produced component layers by a blade fastened on the coating slide, and melt traces are subsequently inscribed in the powder layer by means of a directed beam, so that the powder melts in the melt trace and bonds to underlying component layers, wherein, during the travel of the coating slide in order to apply a new powder layer, perturbations of the travel of the coating slide or components connected thereto are metrologically detected, and in particular the beam melting installation is controlled and/or regulated as a function of the detected measured values. The invention furthermore relates to a device for retrofitting beam melting installations.

Claims

1. A method for producing objects in an additive manufacturing build process in which a layer of powder is spread over a build area with selective melting or sintering of one layer after another of powder in building up of an object, comprising the steps of:

providing an additive manufacturing machine using a powder build material, the additive manufacturing machine including the build area in which the object is generated through layerwise manufacture according to a build process control, and providing a supply of powder to the build area, the additive manufacturing machine further including a coating device for spreading a powder layer across the build area from the supply, the coating device having a bottom surface which is moved in a plane parallel to the surface of the build area to thereby spread the powder build material in the powder layer;

using a sensor on the coating device to determine a surface topography of a previous powder layer through detected movement of the coating device out of the plane of the coating device across the previous powder layer caused by engagement of the coating device with the surface of the previous powder layer; and

then adjusting at least one parameter of the additive manufacturing build process in view of an irregular movement of the coating device during the additive manufacturing build process as determined by the sensor.

2. The method as claimed in claim 1, wherein the irregular movement is detected by at least one of the following alternatives yielding measurement values:

a) metrological detection of perturbations of the coating device or a component connected thereto, by measurement of accelerations and/or of a amplitude and/or frequency, by the sensor on the coating device or the component connected thereto;

b) metrological detection of forces acting against a travel direction on the coating device or the component connected thereto;

by the sensor on the coating device or the component connected thereto;

c) metrological detection of a drive power or the driving currents of a motor, with which the coating device is moved;

d) metrological detection of acoustic sound by a microphone;

e) metrological detection of deflections of the coating device or the component connected thereto by at least one strain gauge.

3. The method as claimed in claim 2, wherein the perturbations or measurement values are only detected within a subregion of an overall travel distance of the coating device, all objects to be produced being arranged inside the subregion.

4. The method as claimed in claim 2, wherein the detected measurement values are checked for exceeding of at least one stored limit value, with different limit-value-dependent actions being initiated for a plurality of predetermined limit values.

5. The method as claimed in claim 2, further comprising, when a predetermined limit value is exceeded, generating an emergency stop of the additive manufacturing build process.

6. An additive manufacturing machine for producing objects in an additive manufacturing build process in which a layer of powder build material is spread over a build area with selective melting or sintering of one layer after another of powder in building up of an object, the machine including the build area in which the object is generated through layerwise manufacture according to a build process control, and a supply of powder build material to the build area, the additive manufacturing machine further comprising:

a coating device for spreading a powder layer across the build area from the supply, the coating device having a bottom surface which is moved in a plane parallel to the surface of the build area to thereby spread the powder build material in the layer; and

a sensor on the coating device to determine a surface topography of a previous powder layer through detected movement of the coating device out of the plane of the coating device across the previous powder layer caused by engagement of the coating device with the surface of the previous powder layer,

wherein the additive manufacturing machine is configured to adjust at least one parameter of the additive manufacturing build process to in view of an irregular movement of the coating device constituting an undesired deviation to the additive manufacturing build process as determined by the sensor.

7. The apparatus of claim 6, further comprising at least one sensor on the coating device or on a component connected thereto, by which the perturbations and/or deflections of the coating device, or of the component connected thereto, occurring during a travel can be metrologically detected.