# US 11,077,463 B2 · Method for the layered manufacturing of a structural component and device > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,077,463 B2 - Document ID: US11077463B2 - Status: Granted - Kind: B2 - Application number: 13/989,270 - Filed: 2011-11-10 - Published: 2013-10-24 - Granted: 2021-08-03 - Earliest claimed: 2010-11-26 - Assignees: MTU Aero Engines AG - Applicants: Thomas Hess; Erwin Bayer - Inventors: Thomas Hess; Erwin Bayer - Web page: https://patentgrep.com/patent/US11077463B2 ## CPC - B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting - B05D 3/06: by exposure to radiation (B05D3/02 takes precedence {; plasma treatment B05D3/141}) - B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] - B22F 12/67: Blades - B22F 12/90: Means for process control, e.g. cameras or sensors - Y02P 10/25: Process efficiency - 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract The invention relates to a method for the layered manufacturing of a structural component from powder, comprising the following steps: establishing at least one parameter (t) of a depression (1) in a produced layer (2) of the structural component; smoothing out the depression (1) if the at least one parameter (t) exceeds a predetermined value; and filling the smoothed-out depression (1) with powder (13). ## Claims ### Claim 1 A method of manufacturing a structural component from a powder, wherein the method comprises forming the structural component layer by layer by a process which comprises melting a first layer of powder to form a first layer of the structural component and forming a second layer of the structural component on the formed first layer by melting a second layer of powder applied on the formed first layer and wherein the method further comprises: detecting at least one parameter of an unfilled depression in a formed layer of the structural component; smoothing the unfilled depression if the at least one parameter exceeds a predetermined value; and filling the smoothed unfilled depression with powder. ### Claim 2 (depends on 1) The method of claim 1, wherein the at least one parameter represents a depth of the unfilled depression. ### Claim 3 (depends on 2) The method of claim 2, wherein the at least one parameter is determined in dependence on a return radiation of a laser beam or an electron beam that scans the unfilled depression. ### Claim 4 (depends on 3) The method of claim 3, wherein the at least one parameter is determined in dependence on a peripheral radiation of the return radiation. ### Claim 5 (depends on 1) The method of claim 1, wherein the at least one parameter is determined in dependence on a return radiation of a laser beam or an electron beam that scans the unfilled depression. ### Claim 6 (depends on 5) The method of claim 5, wherein the at least one parameter is determined in dependence on a peripheral radiation of the return radiation. ### Claim 7 (depends on 1) The method of claim 1, wherein the unfilled depression is smoothed by a laser beam. ### Claim 8 (depends on 7) The method of claim 7, wherein an input of energy for melting the powder filling the unfilled depression is greater than an input of energy in regions adjoining the unfilled depression. ### Claim 9 (depends on 1) The method of claim 1, wherein the unfilled depression is smoothed by an electron beam. ### Claim 10 (depends on 9) The method of claim 9, wherein an input of energy for melting the powder filling the unfilled depression is greater than an input of energy in regions adjoining the unfilled depression. ### Claim 11 (depends on 1) The method of claim 1, wherein smoothing is performed by repeatedly melting the unfilled depression. ### Claim 12 (depends on 1) The method of claim 1, wherein an input of energy for melting the powder filling the unfilled depression is greater than an input of energy in regions adjoining the unfilled depression. ### Claim 13 (depends on 12) The method of claim 12, wherein the method further comprises providing the powder for filling the unfilled depression as part of a powder for a second layer of powder that covers the formed first layer. ### Claim 14 (depends on 13) The method of claim 13, wherein the first layer of powder is melted by at least one of a laser beam and an electron beam. ### Claim 15 (depends on 1) The method of claim 1, wherein the at least one parameter is detected concurrently with forming the layer. ### Claim 16 (depends on 15) The method of claim 15, wherein the at least one parameter is determined in dependence on a return radiation of a laser beam or an electron beam that scans the unfilled depression. ### Claim 17 (depends on 1) The method of claim 1, wherein the method further comprises providing the powder for filling the unfilled depression as part of a powder for a second layer of powder that covers the formed first layer. ### Claim 18 (depends on 17) The method of claim 17, wherein the first layer of powder is melted by at least one of a laser beam and an electron beam. ### Claim 19 (depends on 17) The method of claim 17, wherein the first layer of powder is melted by a laser beam. ### Claim 20 (depends on 17) The method of claim 17, wherein the first layer of powder is melted by an electron beam.