Concept Laser GmbH

Method for operating at least one apparatus ( 1 ) for additively manufacturing three-dimensional objects ( 2 ) by means of successive layerwise selective irradiation and consolidation of layers of a powdered build material ( 3 ) which can be consolidated by means of an energy beam ( 4 ), whereby waste thermal energy (WTE) is generated during operation of the at least one apparatus ( 1 ), characterized in that the waste thermal energy (WTE) is at least partly used for generating electrical or mechanical energy (EE, ME) by means of at least one energy converting device ( 15 ) and/or the waste thermal energy (WTE) is at least partly used for operating at least one thermal energy consuming device.

A method may of additively manufacturing a three-dimensional object includes determining a plurality of scanning segments for a build plane and/or for one or more object layers respectively corresponding to one or more regions of a powder bed defining the build plane, and determining an irradiation vector for irradiating the scanning segments with an energy beam. The irradiation vector determined for the respective scanning segments may include a hatching vector and/or a plurality of scanning vectors defining the hatching vector. The hatching vector and/or the scanning vectors defining the hatching vector may be oriented away from a normal point on the build plane. The method may include outputting an irradiation control command to an energy beam system based on the scanning segments and/or the irradiation vector for irradiating the scanning segments.

A process monitoring system for an additive manufacturing apparatus includes a scanner, a sensor device, and an optical focus-tracking device. The scanner includes an optical adjustment device that directs a melting beam emitted by a laser melting device onto a construction plane to generate a melting section of the construction plane. The sensor device may detect reflected radiation from the melting section and generate sensor data indicative of a size, shape, and/or temperature corresponding to the melting section. The optical focus-tracking device includes a focusing lens located between the scanner and the sensor device. The focusing lens may be actuatable by electronic machine data derived from the sensor data to impart a first focus adjustment with respect to the reflected radiation detected by the sensor followed by a second focus adjustment with respect to the melting beam directed by the optical adjustment device.

Determination device for determining at least one parameter of an energy beam, in particular an energy beam generated via an irradiation device of an apparatus for additively manufacturing three-dimensional objects, which determination device comprises two determination units arrangeable or arranged in succession in a beam path of the energy beam, characterized in that each determination unit builds or comprises at least one complementary pattern element, wherein at least two pattern elements of the two determination units complement each other to a superordinate pattern.

The invention relates to a method for producing a three-dimensional component by an electron-beam, laser-sintering or laser-melting process, in which the component is created by successively solidifying predetermined portions of individual layers of building material that can be solidified by being exposed to the effect of an electron-beam or laser-beam source ( 2 ) by melting on the building material, wherein thermographic data records are recorded during the production of the layers, respectively characterizing a temperature profile of at least certain portions of the respective layer, and the irradiation of the layers takes place by means of an electron beam or laser beam ( 3 ), which is controlled on the basis of the recorded thermographic data records in such a way that a largely homogeneous temperature profile is produced, wherein, to irradiate an upper layer, a focal point ( 4 ) of the electron beam or laser beam ( 3 ) is guided along a scanning path ( 17 ), which is chosen on the basis of the data record characterizing the temperature profile of at least certain portions of the layer lying directly thereunder or on the basis of the data records characterizing the temperature profiles of at least certain portions of the layers lying thereunder.

A fluid flow apparatus configured to provide a flow of fluid with particular flow profiles to a process chamber of an additive manufacturing apparatus is provided. The fluid flow apparatus includes a plurality of openings forming a first flow region, a second flow region, a third flow region, and a fourth flow region in adjacent arrangement along an axis in the process chamber between the build platform and the laser window. A fluid flows, via the second flow region, along a second distance along the axis at a second velocity range between approximately 1.0 meters per second (m/s) and 6.0 m/s, and another flow of fluid flows, via the fourth flow region, along a fourth distance along the axis at a fourth velocity range between approximately 0.1 m/s and 4.5 m/s.

An additive manufacturing machine includes an energy beam system configured to emit an energy beam utilized in an additive manufacturing process, and one or more optical elements utilized by, or defining a portion of, the energy beam system and/or an imaging system of the additive manufacturing machine. The imaging system monitors one or more operating parameters of the additive manufacturing process. A light source is configured to emit an assessment beam that follows an optical path incident upon the one or more optical elements. One or more light sensors detect a reflected beam comprising at least a portion of the assessment beam at a perimeter edge of the one or more optical elements. A control system determines, based at least in part on assessment data comprising data from the one or more light sensors, whether at least one of the one or more optical elements exhibits an optical anomaly. A light source is configured to emit an assessment beam that follows an optical path incident upon the first and second optical elements. One or more light sensors detect a reflected beam that is either internally reflected by the first optical element or reflectively propagated between the first and second optical elements. A control system determines, based at least in part on assessment data comprising data from the one or more light sensors, whether at least one of the first and second optical elements exhibits an optical anomaly.

A fluid flow apparatus configured to provide a flow of fluid with particular flow profiles to a process chamber of an additive manufacturing apparatus is provided. The fluid flow apparatus includes a plurality of openings forming a first flow region, a second flow region, a third flow region, and a fourth flow region in adjacent arrangement along an axis in the process chamber between the build platform and the laser window. A controller is configured to execute instructions that perform operations that include flowing, via the second flow region, the flow of fluid along a second distance along the axis at a second velocity range between approximately 1.0 meters per second (m/s) and 6.0 m/s, and flowing, via the fourth flow region, another flow of fluid along a fourth distance along the axis at a fourth velocity range between approximately 0.1 m/s and 4.5 m/s.

A build unit for additively manufacturing three-dimensional objects may include an energy beam system having one or more irradiation devices respectively configured to direct one or more energy beams onto a region of a powder bed, and an inertization system including an irradiation chamber defining an irradiation plenum, one or more supply manifolds, and a return manifold. The one or more supply manifolds may include a downflow manifold configured to provide a downward flow of a process gas through at least a portion of the irradiation plenum, and/or a crossflow manifold configured to provide a lateral flow of the process gas through at least a portion of the irradiation plenum. The return manifold may evacuate process gas from the irradiation plenum. While irradiating the region of the powder bed, the process gas may flow through the one or more supply manifolds, into the irradiation plenum, and into the return manifold.

An additive manufacturing machine includes an energy beam system configured to emit an energy beam utilized in an additive manufacturing process, and first and second optical elements utilized by, or defining a portion of, the energy beam system and/or an imaging system of the additive manufacturing machine. The imaging system monitors one or more operating parameters of the additive manufacturing process. A light source is configured to emit an assessment beam that follows an optical path incident upon the first and second optical elements. One or more light sensors detect a reflected beam that is either internally reflected by the first optical element or reflectively propagated between the first and second optical elements. A control system determines, based at least in part on assessment data comprising data from the one or more light sensors, whether at least one of the first and second optical elements exhibits an optical anomaly.