IP Library Granted Patent US 11,292,060
Granted Patent B2
US 11,292,060 · App. 17/003,424 · Granted Apr 5, 2022

Method for producing a three-dimensional component

Inventors: Frank Herzog (Lichtenfels, DE); Florian Bechmann (Lichtenfels, DE); Sebastian Berumen (Mursbach, DE); Jean Pierre Kruth (Leuven, BE); Tom Craeghs (Heverlee, BE)
Assignee: CONCEPT LASER GMBH
B22F10/20B23K26/0622B23K26/705B23K31/12B23K31/125B29C64/153B29C64/386B33Y10/00B33Y30/00B22F10/30B33Y40/00Y02P10/25
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Quick Facts
Patent No.
US 11,292,060
App. No.
17/003,424
Granted
Apr 5, 2022
Kind
B2
Abstract

Additive manufacturing systems may include a laser melting apparatus, a sensor device, and a visualization apparatus. A laser melting apparatus may form a three-dimensional component by exposing a powder bed to a beam of radiation based on build coordinates, with the beam of radiation providing an energy influx that generates a melt pool in a melt region of the powder bed. A sensor device may capture sensor values corresponding to the melt pool and/or the melt region. A visualization apparatus may display a representation of the three-dimensional component, with the display including the build coordinates and the sensor values in respect of a capture location thereof in the three-dimensional component. The displayed representation may be based on a display output that includes sensor values correlated with build coordinates.

Claims (33)

1. An additive manufacturing system, comprising:

a laser melting apparatus configured to form a three-dimensional component by exposing a powder bed to a beam of radiation based at least in part on build coordinates for the three-dimensional component, the beam of radiation providing an energy influx that generates a melt pool in a melt region of the powder bed;

a sensor device operably configured to capture sensor values corresponding to the melt pool and/or the melt region;

a visualization apparatus configured to display, based at least in part on a display output, a two-dimensional and/or a multidimensional representation of the three-dimensional component comprising the build coordinates and the sensor values in respect of a capture location thereof in the three-dimensional component, the display output comprising the sensor values having been correlated with the build coordinates.

2. The additive manufacturing system of claim 1 , wherein the two-dimensional and/or the multidimensional representation comprises image data of the three-dimensional component.

3. The additive manufacturing system of claim 2 , wherein the two-dimensional and/or the multidimensional representation comprises the sensor values mapped to the image data of the three-dimensional component.

4. The additive manufacturing system of claim 1 , comprising:

a storage apparatus configured to determine the size of the melt pool based at least in part on specific parts of an electromagnetic spectrum of a beam of radiation emitted by the melt pool having been selected from the sensor values.

5. The additive manufacturing system of claim 1 , wherein the build coordinates are substituted and/or augmented with newly obtained coordinate values, and wherein the sensor is configured to capture the newly obtained coordinate values.

6. The additive manufacturing system of claim 1 , wherein the two-dimensional and/or the multidimensional representation comprises one or more component regions having a deviation from an intended value being selectively displayed and/or highlighted.

7. The additive manufacturing system of claim 6 , wherein the intended value corresponds to a degree of solidification, a degree of fusion, a melt temperature, a density, an energy influx, and/or a melt pool dimension.

8. The additive manufacturing system of claim 1 , wherein the sensor values are used to accept, reject, or modify the three-dimensional component.

9. The additive manufacturing system of claim 1 , wherein the sensor values are used to determine for the melt region of the powder bed when the melt pool solidifies, a degree of fusion, a temperature, and/or a temperature profile.

10. A method of additively manufacturing a three-dimensional component, the method comprising:

correlating sensor values with build coordinates for a three-dimensional component, the laser apparatus configured to form the three-dimensional component by exposing a powder bed to a beam of radiation based at least in part on the build coordinates, the beam of radiation providing an energy influx that generates a melt pool in a melt region of the powder bed, the sensor values having been captured by a sensor device and corresponding to the melt pool and/or the melt region; and

displaying with a visualization apparatus, based at least in part on a display output, a two-dimensional and/or a multidimensional representation of the three-dimensional component comprising the build coordinates and the sensor values in respect of a capture location thereof in the three-dimensional component, the display output comprising the sensor values having been correlated with the build coordinates.

11. The method of claim 10 , wherein the two-dimensional and/or the multidimensional representation comprises image data of the three-dimensional component.

12. The method of claim 11 , wherein the two-dimensional and/or the multidimensional representation comprises the sensor values mapped to the image data of the three-dimensional component.

13. The method of claim 10 , comprising:

determining, with a storage apparatus, the size of the melt pool based at least in part on specific parts of an electromagnetic spectrum of a beam of radiation emitted by the melt pool having been selected from the sensor values.

14. The method of claim 10 , comprising:

substituting and/or augmenting the build coordinates with newly obtained coordinate values, the newly obtained coordinate values having been captured by the sensor.

15. The method of claim 10 , wherein the two-dimensional and/or the multidimensional representation comprises one or more component regions having a deviation from an intended value being selectively displayed and/or highlighted.

16. The method of claim 15 , wherein the intended value corresponds to a degree of solidification, a degree of fusion, a melt temperature, a density, an energy influx, and/or a melt pool dimension.

17. The method of claim 10 , comprising:

accepting, rejecting, and/or modifying the three-dimensional component based at least in part on the sensor values.

18. The method of claim 10 , comprising:

using the sensor values to determine for the melt region of the powder bed when the melt pool solidifies, a degree of fusion, a temperature, and/or a temperature profile.

19. The method of claim 10 , comprising:

modifying the three-dimensional object during formation thereof based at least in part on the sensor values.

20. A computer-readable medium comprising computer-executable instructions, which when executed by a processor associated with an apparatus for additively manufacturing a three-dimensional component, causes the apparatus to perform a method comprising:

correlating sensor values with build coordinates for a three-dimensional component, the laser apparatus configured to form the three-dimensional component by exposing a powder bed to a beam of radiation based at least in part on the build coordinates, the beam of radiation providing an energy influx that generates a melt pool in a melt region of the powder bed, the sensor values having been captured by a sensor device and corresponding to the melt pool and/or the melt region; and

displaying with a visualization apparatus, based at least in part on a display output, a two-dimensional and/or a multidimensional representation of the three-dimensional component comprising the build coordinates and the sensor values in respect of a capture location thereof in the three-dimensional component, the display output comprising the sensor values having been correlated with the build coordinates.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 26, 2020
From: HERZOG, FRANK; BECHMANN, FLORIAN
To: CONCEPT LASER GMBH
Reel/Frame 053605/0315 →
MERGER AND CHANGE OF NAME Recorded Aug 26, 2020
From: CL SCHUTZRECHTSVERWALTUNGS GMBH; CONCEPT LASER GMBH
To: CONCEPT LASER GMBH
Reel/Frame 053607/0107 →
Priority Claims (1)
DE 202010010771.7 · Jul 28, 2010 · national
Continuity (2)
Continuation 13812446
Related Publication 20200391291A1 · Dec 17, 2020