Energy beam position verification

• US 9,341,467 B2
• Filed: 06/25/2015
• Issued: 05/17/2016
• Est. Priority Date: 08/20/2014
• Status: Active Grant

• Current Assignee: Arcam Ab (Danaher Corporation)
• Original Assignee: Arcam Ab (Danaher Corporation)
• Inventors: Snis, Anders
• Primary Examiner(s): Kim, Kiho
• Application Number:
  US14/750,713
• Publication Number:
  US 20160054115A1
• Time in Patent Office: 327 Days
• US Class Current: 1/1
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/31 Calibration of process steps or apparatus settings, e.g. before or during manufacturing
• CPC Class Codes: B22F 12/52 Hoppers
• CPC Class Codes: B22F 12/90 Means for process control, e.g. cameras or sensors
• CPC Class Codes: B23K 15/0013 Positioning or observing workpieces, e.g. with respect to the impact; Aligning, aiming or focusing electronbeams
• CPC Class Codes: B23K 15/0086 welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 15/02 Control circuits therefor
• CPC Class Codes: B23K 26/032 using optical means
• CPC Class Codes: B23K 26/04 Automatically aligning, aiming or focusing the laser beam, e.g. using the back-scattered light
• CPC Class Codes: B23K 26/046 Automatically focusing the laser beam
• CPC Class Codes: B23K 26/082 Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
• CPC Class Codes: B23K 26/342 Build-up welding
• CPC Class Codes: B23K 26/70 Auxiliary operations or equipment
• 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 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: G01B 11/00 Measuring arrangements characterised by the use of optical techniques
• CPC Class Codes: G01B 11/14 for measuring distance or clearance between spaced objects or spaced apertures G01B11/26 takes precedence; rangefinders G01C3/00
• CPC Class Codes: G01B 15/00 Measuring arrangements characterised by the use of electromagnetic waves or particle radiation, e.g. by the use of microwaves, X-rays, gamma rays or electrons characterised by the use of optical techniques G01B9/00, G01B11/00
• CPC Class Codes: G01M 11/02 : Testing optical properties
• CPC Class Codes: G01P 21/00 : Testing or calibrating of apparatus or devices covered by the preceding groups
• CPC Class Codes: G01P 3/36 : Devices characterised by the use of optical means, e.g. using infrared, visible, or ultraviolet light G01P3/68 takes precedence; gyrometers using the Sagnac effect, i.e. rotation-induced shifts between counter-rotating electromagnetic beams G01C19/64
• CPC Class Codes: H01J 37/244 : Detectors; Associated components or circuits therefor
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A method for verifying a position of an energy beam spot, said method comprising the steps of: providing a calibrated energy beam having a first focus in a at least two positions at a work table, detecting said at least two positions of said energy beam spot on said work table created with said energy beam having said first focus, providing said calibrated energy beam having a second focus in said at least two positions at a work table, detecting said at least two positions of said energy beam spot on said work table created with said energy beam having said second focus, comparing said at least two positions created with said first and second focus, wherein said position of the energy beam is verified if said positions created with said first focus are deviating less than a predetermined distance from said positions created with said second focus.

Claims

1. A non-transitory computer program product comprising at least one non-transitory computer-readable storage medium having computer-readable program code portions embodied therein, the computer-readable program code portions comprising:

at least one executable portion configured for;

providing said energy beam having a first focus in at least two positions on said work table,

detecting said at least two positions of said energy beam spot on said work table created with said energy beam having said first focus,

providing said energy beam having a second focus in said at least two positions on said work table, and

detecting said at least two positions of said energy beam spot on said work table created with said energy beam having said second focus, and

at least one executable portion configured for comparing said at least two positions created with said first and second focuses, wherein said position of the energy beam is verified if said at least two positions created with said first focus are deviating less than a predetermined distance from said at least two positions created with said second focus.

2. The non-transitory computer program product of claim 1, wherein:

said computer program product is configured for verifying a deflection speed; and

said computer program product further comprises;

an executable portion configured for generating a predetermined pattern on a work table with said energy beam spot while deflecting said energy beam spot with a first deflection speed;

an executable portion configured for detecting first positions of said energy beam spot on said work table created with said first deflection speed;

an executable portion configured for generating said predetermined pattern on a work table with said energy beam spot while deflecting said energy beam spot with a second deflection speed;

an executable portion configured for detecting second positions of said energy beam spot on said work table created with said second deflection speed; and

an executable portion configured for comparing said first and second positions, wherein said deflection speed is verified if each one of said first positions are deviating less than a predetermined distance from corresponding ones of said second positions.

3. The non-transitory computer program product of claim 2, wherein:

said computer program product is configured for verifying a beam spot size; and

said computer program product further comprises;

an executable portion configured for generating a first energy beam spot from a first energy beam source having a predetermined size and power at a first position on a work piece,

an executable portion configured for varying at least one of a focus lens setting or an astigmatism lens setting for said first energy beam spot until max intensity for the first beam spot is detected,

an executable portion configured for comparing at least one setting of said focus lens and/or astigmatism lens for said detected maximum intensity of the first energy beam spot with corresponding stored settings of said focus lens and/or astigmatism lens for the first energy beam spot with said predetermined size and power,

an executable portion configured for repeating said generating, varying, and comparing steps for different predetermined beam powers, and

an executable portion configured for repeating said generating, varying, comparing, and said repetition thereof steps for different positions on said work piece, wherein said first energy beam spot size is verified if each detected settings of said focus lens and/or astigmatism lens are deviating less than a predetermined value from corresponding stored settings of said focus lens and/or astigmatism lens.

4. The non-transitory computer program product of claim 1, wherein:

said computer program product is configured for verifying a beam spot size; and

said computer program product further comprises;

an executable portion configured for generating a first energy beam spot from a first energy beam source having a predetermined size and power at a first position on a work piece,

an executable portion configured for varying at least one of a focus lens setting or an astigmatism lens setting for said first energy beam spot until max intensity for the first beam spot is detected,

an executable portion configured for comparing at least one setting of said focus lens and/or astigmatism lens for said detected maximum intensity of the first energy beam spot with corresponding stored settings of said focus lens and/or astigmatism lens for the first energy beam spot with said predetermined size and power,

an executable portion configured for repeating said generating, varying, and comparing steps for different predetermined beam powers, and

an executable portion configured for repeating said generating, varying, comparing, and said repetition thereof steps for different positions on said work piece, wherein said first energy beam spot size is verified if each detected settings of said focus lens and/or astigmatism lens are deviating less than a predetermined value from corresponding stored settings of said focus lens and/or astigmatism lens.

5. An apparatus for verifying a position of an energy beam spot, said apparatus comprising:

at least one energy beam source configured to generate at least one energy beam; and

a control unit configured to;

provide said at least one energy beam having a first focus in at least two positions on a work table,

detect said at least two positions of said energy beam spot on said work table created with said at least one energy beam having said first focus,

provide said at least one energy beam having a second focus in said at least two positions on a work table,

detect said at least two positions of said energy beam spot on said work table created with said at least one energy beam having said second focus, and

compare said at least two positions created with said first and second focuses, wherein said position of the energy beam is verified if said at least two positions created with said first focus are deviating less than a predetermined distance from said at least two positions created with said second focus.

6. The apparatus of claim 5, wherein:

the apparatus is further configured for verifying a deflection speed of said first energy beam spot; and

the control unit is further configured to;

generate a predetermined pattern on a work table with said energy beam spot while deflecting said energy beam spot with a first deflection speed;

detect first deflection positions of said energy beam spot on said work table created with said first deflection speed;

generate said predetermined pattern on a work table with said energy beam spot while deflecting said energy beam spot with a second deflection speed;

detect second deflection positions of said energy beam spot on said work table created with said second deflection speed; and

compare said first and second deflection positions, wherein said deflection speed is verified if each one of said first deflection positions are deviating less than a predetermined distance from corresponding ones of said second deflection positions.

7. The apparatus of claim 6, wherein:

the apparatus is further configured for verifying a size of at least one energy beam spot; and

the control unit is further configured to;

vary at least one of a focus lens setting or an astigmatism lens setting for said first energy beam spot until max intensity for the first beam spot is detected,

compare at least one setting of said focus lens and/or astigmatism lens for said detected maximum intensity of the first energy beam spot with corresponding stored settings of said focus lens and/or astigmatism lens for the first energy beam spot with said predetermined size and power,

repeat said generating, varying, and comparing steps for one or more beam powers other than said predetermined beam power, and

repeat said generating, varying, comparing, and the above repeating steps for one or more positions on said work piece other than said first position, wherein said first energy beam spot size is verified if each detected settings of said focus lens and/or astigmatism lens are deviating less than a predetermined value from corresponding stored settings of said focus lens and/or astigmatism lens.

8. The apparatus of claim 5, wherein:

the apparatus is further configured for verifying a size of at least one energy beam spot; and

the control unit is further configured to;

vary at least one of a focus lens setting or an astigmatism lens setting for said first energy beam spot until max intensity for the first beam spot is detected,

compare at least one setting of said focus lens and/or astigmatism lens for said detected maximum intensity of the first energy beam spot with corresponding stored settings of said focus lens and/or astigmatism lens for the first energy beam spot with said predetermined size and power,

repeat said generating, varying, and comparing steps for one or more beam powers other than said predetermined beam power, and

repeat said generating, varying, comparing, and the above repeating steps for one or more positions on said work piece other than said first position, wherein said first energy beam spot size is verified if each detected settings of said focus lens and/or astigmatism lens are deviating less than a predetermined value from corresponding stored settings of said focus lens and/or astigmatism lens.

9. A method for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together with at least one energy beam so as to form the article, said method comprising the steps of:

generating a model of said three dimensional article,

applying a first powder layer on a work table,

directing said energy beam from at least one energy beam source over said work table, causing said first powder layer to fuse in selected locations according to said model to form a first cross section of said three dimensional article, said method further comprising a verification method for verifying a position of said energy beam used for fusing said powder material, said verification method comprising the steps of;

providing said energy beam having a first focus in at least two positions on said work table,

detecting said at least two positions of said energy beam spot on said work table created with said energy beam having said first focus,

providing said energy beam having a second focus in said at least two positions on said work table,

detecting said at least two positions of said energy beam spot on said work table created with said energy beam having said second focus, and

comparing said at least two positions created with said first and second focuses, wherein said position of the energy beam is verified if said at least two positions created with said first focus are deviating less than a predetermined distance from said at least two positions created with said second focus.

10. The method according to claim 9, wherein said verification method is performed before each layer of said three-dimensional article is fused.

11. The method according to claim 10, wherein said verification method is performed while applying powder on said work table.

12. The method according to claim 9, wherein said verification method is performed on at least one of fused areas or non-fused areas.