Method and device for generating control data for an additive manufacturing device

A method for generating control data for a device for additive manufacturing of a manufactured product in a manufacturing process in which build-up material is built up and selectively solidified, wherein, for solidifying on a build field, irradiating of the build-up material with at least one energy beam takes place, wherein an impingement surface of the energy beam on the build field is moved in order to melt the build-up material in a target area in and around the impingement surface, the method comprising:

• defining optimization criteria and/or secondary and/or boundary conditions relating to a local target temperature distribution in the target area of the build-up material for generating the control data for at least one irradiation mode, at which temperature distribution a melting of the build-up material within the target area is caused by heat conduction welding, and on the basis of the optimization criteria and/or secondary and/or boundary conditions, at least one optimized intensity profile of the energy beam is determined, wherein the optimized intensity profile of the energy beam at the impingement surface on the build field is substantially non-rotationally symmetric with respect to a beam axis running coaxially to the direction of incidence of the energy beam;
• and
• generating the control data upon activating the device for additive manufacturing in the irradiation mode to irradiate the build-up material with an energy beam having substantially the determined optimized intensity profile,
• wherein at least one of the following process parameters is additionally determined based on the optimization criteria and/or secondary and/or boundary conditions:
• radiation intensity;
• at least one beam expansion and/or shape at the impingement surface of the energy beam on the build field;
• movement speed of the impingement surface of the energy beam on the build field;
• layer thickness;
• and
• irradiation strategy.

A method for generating control data for a device for additive manufacturing of a manufactured product in a manufacturing process in which build-up material is built up and selectively solidified, wherein, for solidifying on a build field, irradiating of the build-up material with at least one energy beam takes place, wherein an impingement surface of the energy beam on the build field is moved in order to melt the build-up material in a target area in and around the impingement surface, the method comprising:

• defining optimization criteria and/or secondary and/or boundary conditions relating to a local target temperature distribution in the target area of the build-up material for generating the control data for at least one irradiation mode, at which temperature distribution a melting of the build-up material within the target area is caused by heat conduction welding, and on the basis of the optimization criteria and/or secondary and/or boundary conditions, at least one optimized intensity profile of the energy beam is determined, wherein the optimized intensity profile of the energy beam at the impingement surface on the build field is substantially non-rotationally symmetric with respect to a beam axis running coaxially to the direction of incidence of the energy beam;
• and
• generating the control data upon activating the device for additive manufacturing in the irradiation mode to irradiate the build-up material with an energy beam having substantially the determined optimized intensity profile,
• further comprising considering at least one member from the group consisting of the following when defining the optimization criteria and/or secondary and/or boundary conditions:
• characteristic values for describing phase transformations of the build-up material;
• cooling rates and temperature holding points of the build-up material;
• spatial temperature gradients of the build-up material;
• a thermal conduction coefficient of the build-up material;
• a heat capacity of the build-up material;
• a density of the build-up material;
• a thermal conductivity of the build-up material;
• a surface tension of the build-up material;
• phase transformation enthalpies of the build-up material;
• boiling or evaporation temperature of the build-up material;
• and
• a melting temperature of the build-up material.

A method for generating control data for a device for additive manufacturing of a manufactured product in a manufacturing process in which build-up material is built up and selectively solidified, wherein, for solidifying on a build field, irradiating of the build-up material with at least one energy beam takes place, wherein an impingement surface of the energy beam on the build field is moved in order to melt the build-up material in a target area in and around the impingement surface, the method comprising:

• defining optimization criteria and/or secondary and/or boundary conditions relating to a local target temperature distribution in the target area of the build-up material for generating the control data for at least one irradiation mode, at which temperature distribution a melting of the build-up material within the target area is caused by heat conduction welding, and on the basis of the optimization criteria and/or secondary and/or boundary conditions, at least one optimized intensity profile of the energy beam is determined, wherein the optimized intensity profile of the energy beam at the impingement surface on the build field is substantially non-rotationally symmetric with respect to a beam axis running coaxially to the direction of incidence of the energy beam;
• and
• generating the control data upon activating the device for additive manufacturing in the irradiation mode to irradiate the build-up material with an energy beam having substantially the determined optimized intensity profile,
• wherein for defining the optimization criteria and/or secondary and/or boundary conditions relating to a local target temperature distribution at least one of the following target variables is determined:
• a temporal temperature development;
• a local target temperature gradient;
• a target molten pool depth;
• a target surface quality;
• a target build rate;
• a deviation from the maximum temperature;
• and
• a target molten pool shape.

A method for generating control data for a device for additive manufacturing of a manufactured product in a manufacturing process in which build-up material is built up and selectively solidified, wherein, for solidifying on a build field, irradiating of the build-up material with at least one energy beam takes place, wherein an impingement surface of the energy beam on the build field is moved in order to melt the build-up material in a target area in and around the impingement surface, the method comprising:

• defining optimization criteria and/or secondary and/or boundary conditions relating to a local target temperature distribution in the target area of the build-up material for generating the control data for at least one irradiation mode, at which temperature distribution a melting of the build-up material within the target area is caused by heat conduction welding, and on the basis of the optimization criteria and/or secondary and/or boundary conditions, at least one optimized intensity profile of the energy beam is determined, wherein the optimized intensity profile of the energy beam at the impingement surface on the build field is substantially non-rotationally symmetric with respect to a beam axis running coaxially to the direction of incidence of the energy beam;
• and
• generating the control data upon activating the device for additive manufacturing in the irradiation mode to irradiate the build-up material with an energy beam having substantially the determined optimized intensity profile,
• wherein at least one of the secondary and/or boundary conditions relates to the fulfillment of at least one of the following parameters or specifications:
• a maximum temperature;
• a minimum temperature;
• a continuous temperature profile at a boundary between two adjacent process zones;
• and
• a minimum meltpool depth.

A control data generating device for generating control data for a device for additive manufacturing of a manufactured product in a manufacturing process in which build-up material is built up and selectively solidified, wherein, for solidifying on a build field, irradiating the build-up material with at least one energy beam takes place, wherein an impingement surface of the energy beam on the build field is moved in order to melt the build-up material in a target area in and around the impingement surface, the device comprising:

• a defining module for defining optimization criteria and/or secondary and/or boundary conditions relating to a local target temperature distribution in the target area of the build-up material for generating the control data for at least one irradiation mode, at which temperature distribution a melting of the build-up material within the target area is caused by heat conduction welding, and on the basis of the optimization criteria and/or secondary and/or boundary conditions, at least one optimized intensity profile of the energy beam is determined, wherein the optimized intensity profile of the energy beam at the impingement surface on the build field is substantially non-rotationally symmetric and is non-Gaussian shaped with respect to a beam axis running coaxially to the direction of incidence of the energy beam;
• and
• a control data generating module for generating the control data upon activating the device for additive manufacturing in the irradiation mode to irradiate the build-up material with an energy beam having substantially the determined optimized intensity profile.