Method and arrangement for producing a workpiece by using additive manufacturing techniques

• US 10,532,513 B2
• Filed: 02/25/2019
• Issued: 01/14/2020
• Est. Priority Date: 09/02/2013
• Status: Active Grant

• Current Assignee: Carl Zeiss Industrial Metrology, LLC (Carl-Zeiss-Stiftung), Carl Zeiss Industrielle Messtechnik GmbH (Carl-Zeiss-Stiftung)
• Original Assignee: Carl Zeiss Industrielle Messtechnik GmbH (Carl-Zeiss-Stiftung)
• Inventors: Bauza, Marcin B., Knebel, Richard H., Engel, Thomas, Haverkamp, Nils, Sagemueller, Rainer, Seitz, Dominik, Held, Tobias
• Primary Examiner(s): Sultana, Nahida
• Application Number:
  US16/284,960
• Publication Number:
  US 20190184631A1
• Time in Patent Office: 323 Days
• 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: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

A method of producing a workpiece by using additive manufacturing techniques includes obtaining computer-aided design data representing the workpiece in multiple layers. The method includes providing build platforms and layer tools. Each layer tool is moveable relative to a respective build platform and configured to generate or solidify a material layer on the respective build platform. The method includes producing a first defined material layer of the workpiece on a first build platform by controlling a first layer tool according to a first layer definition. The method includes transferring the first defined material layer from the first build platform to a second build platform and measuring the first defined material layer using a first measuring head to measure individual characteristics. The method includes producing further material layers of the workpiece by controlling a second layer tool in accordance with further layer definitions as a function of the measured individual characteristics.

Claims

1. A method of producing a workpiece by using additive manufacturing techniques, the method comprising:

obtaining a computer-aided design (CAD) data set representing the workpiece in a plurality of layers, wherein the CAD data set includes a plurality of predefined layer definitions corresponding to the plurality of layers;

providing a plurality of build platforms;

providing a plurality of layer tools, wherein each respective layer tool of the plurality of layer tools is moveable relative to a respective one of the plurality of build platforms, and wherein each respective layer tool of the plurality of layer tools is configured to at least one of generate and solidify a material layer on the respective one of the plurality of build platforms;

providing a plurality of measuring heads, wherein each respective measuring head of the plurality of measuring heads is moveable relative to a respective one of the plurality of build platforms;

producing a first defined material layer of the workpiece on a first build platform of the plurality of build platforms by controlling a first layer tool of the plurality of layer tools in accordance with a first layer definition based on one of the plurality of predefined layer definitions;

transferring the first defined material layer of the workpiece from the first build platform to a second build platform of the plurality of build platforms;

measuring the first defined material layer using a first measuring head of the plurality of measuring heads in order to determine individual characteristics of the first defined material layer while the first defined material layer is situated on the second build platform; and

producing further material layers of the workpiece on the first defined material layer by controlling a second layer tool of the plurality of layer tools in accordance with further layer definitions while the first defined material layer is situated on the second build platform,

wherein the further layer definitions are generated from the plurality of predefined layer definitions as a function of the individual characteristics of the first defined material layer.

2. The method of claim 1, wherein the measuring the first defined material layer comprises determining at least one of geometrical or dimensional characteristics of the first defined material layer.

3. The method of claim 1, wherein the measuring the first defined material layer comprises determining at least one of a density or a temperature distribution of the first defined material layer.

4. The method of claim 1, wherein the measuring is repeated for the further material layers in order to determine further individual characteristics, and wherein the further individual characteristics are used in a closed loop configuration until a final material layer of the workpiece has been produced.

5. The method of claim 1, further comprising:

providing a production database that represents a nominal relationship between a plurality of layer definitions, the plurality of layer tools, and the material layers produced by the plurality of layer tools, wherein the plurality of layer definitions includes the first layer definition and the further layer definitions, wherein the production database is used in the controlling the respective first and second layer tools in accordance with the plurality of layer definitions, and

repeatedly updating the production database in response to the individual characteristics.

6. The method of claim 5, further comprising:

measuring the workpiece after producing a final material layer in order to determine final workpiece characteristics, and

updating the production database in response to the final workpiece characteristics.

7. The method of claim 1, wherein the workpiece is finally measured after all layers of the plurality of layers are produced in order to verify conformance of the workpiece with the CAD data set.

8. The method of claim 1, wherein the producing further material layers comprises at least one of increasing an amount of process material relative to a nominal amount for filling voids in the first defined material layer, decreasing an amount of process material relative to a nominal amount in order to correct for oversize dimensions of the first defined material layer, modifying a movement parameter of the second layer tool relative to the second build platform, or modifying a process temperature.

9. The method of claim 1, wherein the producing further material layers comprises ablating excess material from the first defined material layer using a subtractive manufacturing technique.

10. The method of claim 1, further comprising aborting the producing further material layers in response to the individual characteristics of the first defined material layer exceeding a predefined threshold level.

11. The method of claim 1, wherein each of the plurality of measuring heads comprises at least one of a tactile probe, an optical metrology sensor, or a computer tomography detector.

12. The method of claim 1, wherein the second build platform comprises a distinct datum feature defining a reference point for the measuring head corresponding to the second build platform.

13. The method of claim 1, wherein the first defined material layer comprises a plurality of material layers that are produced on the first build platform.

14. The method of claim 1, wherein the build platforms of the plurality of build platforms are arranged in sequential order.

15. The method of claim 1, wherein:

the first defined material layer is produced using a first defined material, and

the further material layers are produced using at least one further defined material that is different from the first defined material.

16. The method of claim 15, wherein the first defined material and the at least one further defined material are different plastic materials.

17. The method of claim 15, wherein the first defined material is a metal and the at least one further defined material is a plastic material.

18. The method of claim 1, wherein the further material layers form a temporary workpiece support structure that is removed in a later stage of the production process.

19. A method of additive manufacturing to produce a workpiece, the method comprising:

obtaining a machine-readable description of the workpiece, wherein the description includes an ordered series of definitions, each definition defining a corresponding layer of the workpiece; and

creating a series of layers according to the series of definitions, in order, wherein creating a selected layer of the series of layers includes;

obtaining a three-dimensional measurement of a prior layer deposited immediately prior to the selected layer;

determining a deviation between the three-dimensional measurement of the prior layer and the definition of the prior layer;

determining an adjustment to counteract the deviation;

creating an adjusted definition for the selected layer based on the adjustment; and

creating the selected layer based on the adjusted definition.

20. A system for producing a workpiece by using additive manufacturing techniques, the system comprising:

a plurality of build platforms;

a plurality of layer tools, wherein each respective layer tool of the plurality of layer tools is moveable relative to a respective one of the plurality of build platforms, and wherein each respective layer tool of the plurality of layer tools is configured to at least one of generate and solidify a plurality of material layers one on top of the other on a respective one of the plurality of build platforms;

a plurality of measuring heads, with each respective measuring head of the plurality of measuring heads being moveable relative to a respective one of the plurality of build platforms;

a transfer device; and

a control unit comprising (i) a memory configured to store a computer-aided design (CAD) data set representing the workpiece in a plurality of layers and to store a plurality of layer definitions corresponding to the plurality of layers and (ii) a controller configured to drive the plurality of layer tools and the plurality of measuring heads relative to the respective ones of the plurality of build platforms, wherein the control unit is configured to;

control a first layer tool of the plurality of layer tools in accordance with a first layer definition of the plurality of layer definitions in order to produce a first defined material layer of the workpiece on a first build platform of the plurality of build platforms,

transfer the first defined material layer of the workpiece from the first build platform to a second build platform of the plurality of build platforms,

control a measuring head of the plurality of measuring heads in order to determine individual characteristics of the first defined material layer while the first defined material layer is situated on the second build platform, and

modify the plurality of layer definitions in response to the individual characteristics of the first defined material layer in order to produce further material layers of the workpiece on the first defined layer as a function of the individual characteristics of the first defined material layer, while the first defined material layer is situated on the second build platform.