Layer selective exposure in the overhang region in generative manufacturing
AssigneeTRUMPF Laser- und Systemtechnik GmbH
InventorsDominik Maurer, Roland Spiegelhalder
Life of this patent
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Abstract
Methods and systems for generative manufacturing of a three-dimensional component from a powder, wherein a layer structure model of the component to be manufactured is divided into a core region and a shell region adjacent to the core region, and wherein the shell region forms at least a portion of the surface of the three-dimensional component. Then, a layer-based irradiation process is performed in which a density of irradiated powder layers is lower in the shell region than in the core region.
Claims20
A method for generative manufacturing a three-dimensional component from a powder, the method comprising
- dividing a layer structure model of the component to be manufactured into a core region and a shell region adjacent to the core region, wherein the shell region forms at least a portion of the surface of the three-dimensional component;
- and
- performing a layer-based irradiation process based on the layer structure model, in which a density of irradiated powder layers in the shell region is lower than in the core region that is adjacent in the layer plane direction, wherein the density is given by the number of irradiated layers in a direction normal to the powder layers per unit length.
A method for generative manufacturing of a three-dimensional component from a powder, the component having an overhang structure and being manufactured on a building platform by selective laser melting, the method comprising
- providing an irradiation plan based on a layer model of the three-dimensional component, wherein the layer model includes a sequence of layers, each of which is associated with a layer-specific contour of the component, wherein the sequence includes a first subgroup of layers and a second subgroup of layers, which are interleaved in one another, and wherein in the first subgroup of layers in the region of the overhang structure an irradiation of the powder up to the contour is planned, and in the second subgroup of layers in the region of the overhang structure an irradiation of the powder is planned only up to a distance from the contour, and
- performing a sequential application of powder layers on the building platform and irradiating the powder layers with irradiation parameters of the laser beam according to the irradiation plan.
A manufacturing device for generative manufacturing of a three-dimensional component from a powder comprising:
- a manufacturing space providing a work surface and including a platform area;
- a building cylinder, which has a vertically movable support on which the three-dimensional component is to be manufactured in layers on a surface of a building platform;
- a pusher device with a coater for producing powder layers with the powder in a building platform area;
- an irradiation system for generating a beam for irradiating the powder layers in the building platform area to produce the three-dimensional component layer by layer;
- and
- a control unit that, based on irradiation data of an irradiation plan of the three-dimensional component, controls the manufacturing of the three-dimensional component according to a method comprising
- dividing a layer structure model of the component to be manufactured into a core region and a shell region adjacent to the core region, wherein the shell region forms at least a portion of the surface of the three-dimensional component;
- and
- performing a layer-based irradiation process based on the layer structure model, in which a density of irradiated powder layers in the shell region is lower than in the core region that is adjacent in the layer plane direction, wherein the density is given by the number of irradiated layers in a direction normal to the powder layers per unit length,
- wherein in particular the irradiation data define the regions to be irradiated of the powder layers, the regions to be irradiated include a shell region and a core region, and a density of irradiated powder layers is lower in the shell region than in the core region.
Dependencies are inferred from the claim text.