438results about "Additive manufacturing" patented technology

This invention relates to a metal composite orthopedic device. The device can comprise a metallic substrate cladded or joined to one or more metallic layer(s). The substrate and metallic layer(s) can be selected of different metals and metal alloys to provide desired wear performance, imaging characteristics and optionally to serve as a reservoir for therapeutic agents.

The present invention is a medical device for controlling the release of an active agent. The medical device has a supporting structure having a porous body disposed therein. At least one elution rate controlling matrix containing an effective amount of at least one active agent is disposed within the pores of the porous body in a manner that protects the matrix from mechanical damage. The medical device may therefore be used for controlled drug release applications. Additionally, the present invention discloses a method for using the medical device for the treatment and prevention of diseases in mammals. This invention further relates to a method for using the medical device for treating and preventing vascular diseases.

The disclosed method relates to manufacture of a near net-shaped products such as ceramic containing products such as ceramic-metal composites. The method entails forming a mixture of a build material and a binder and depositing that mixture onto a surface to produce a layer of the mixture. An activator fluid then is applied to at least one selected region of the layer to bond the binder to the build material to yield a shaped pattern. These steps may be repeated to produce a porous whitebody that is heat treated to yield a porous greenbody preform having a porosity of about 30% to about 70%. The greenbody then is impregnated with a molten material such as molten metal. Where the build material is SiC, the molten metal employed is Si to generate a SiC—Si composite.

A process for manufacturing a porous metal-containing material is provided. For example, a composition is provided comprising particles dispersed in at least one solvent, the particles comprising at least one polymer material and at least one metal-based compound. The solvent can be substantially removed from the composition, and the polymer material can be substantially decomposed, thereby converting the solvent-free particles into a porous metal-containing material. In addition, metal-containing materials produced in accordance with the above process and their use in implantable medical devices can be provided.

A method of making a combustion turbine component includes assembling a plurality of metallic combustion turbine subcomponent greenbodies together to form a metallic greenbody assembly and sintering the metallic greenbody assembly to thereby form the combustion turbine component. Each of the plurality of metallic combustion turbine subcomponent greenbodies may be formed by direct metal fabrication (DMF). In addition, each of plurality of metallic combustion turbine subcomponent greenbodies may include an activatable binder and the activatable binder may be activated prior to sintering.

Systems and methods for fabricating multi-functional articles comprised of additively formed gradient materials are provided. The fabrication of multi-functional articles using the additive deposition of gradient alloys represents a paradigm shift from the traditional way that metal alloys and metal / metal alloy parts are fabricated. Since a gradient alloy that transitions from one metal to a different metal cannot be fabricated through any conventional metallurgy techniques, the technique presents many applications. Moreover, the embodiments described identify a broad range of properties and applications.

Systems and methods for fabricating multi-functional articles comprised of additively formed gradient materials are provided. The fabrication of multi-functional articles using the additive deposition of gradient alloys represents a paradigm shift from the traditional way that metal alloys and metal / metal alloy parts are fabricated. Since a gradient alloy that transitions from one metal to a different metal cannot be fabricated through any conventional metallurgy techniques, the technique presents many applications. Moreover, the embodiments described identify a broad range of properties and applications.

In a method for manufacturing an article (1), particularly a prototype of a product or component, a tool prototype or spare part, by using selected laser melting, for the application onto the article (1) of a layer (13) or portion of a second metallic material, which is different from the material of the first metallic powder (4), a tape (12), sheet (14), foil or three-dimensional pre-form (18) of a second material is applied to the article (1) and is heated by a focused laser or electron beam (6) to a specified temperature such that the tape (12), sheet (14), foil or pre-form, respectively, are made molten by the electron laser beam (6), wherein the focused beam (6) is applied to a given area corresponding to a selected cross-sectional area of the model of the article (1) under formation of a new layer or part made of second material integral with the article (1).

A method for fabricating an assembly having an airfoil extending radially outwardly from a member includes determining three-dimensional information of the airfoil, converting the three-dimensional information into a plurality of slices that each define a cross-sectional layer of the airfoil, successively forming each layer of the airfoil by fusing a metallic powder using laser energy, and coupling the airfoil to the member such that the airfoil extends radially outward from the member.

A method is disclosed for laser net shape manufacturing a part or repairing an area of a part comprising providing a CAD model of the part to be manufactured or repaired, digitally slicing the CAD model into a plurality of deposition layers, determining a medial axis for each of the deposition layers of the part or repair area; and depositing a bead of a material in a pattern centered upon the medial axis of each of the deposition layers so as to build-up the material by each of the deposition layer until the part is manufactured or repaired.

The present invention is a medical device for controlling the release of an active agent. The medical device has a supporting structure having a porous body disposed therein. At least one elution rate controlling matrix containing an effective amount of at least one active agent is disposed within the pores of the porous body in a manner that protects the matrix from mechanical damage. The medical device may therefore be used for controlled drug release applications. Additionally, the present invention discloses a method for using the medical device for the treatment and prevention of diseases in mammals. This invention further relates to a method for using the medical device for treating and preventing vascular diseases.

A method of building or repair of a hollow superalloy component (20, 61) by forming an opening (38, 62) in a wall (28) of the component; filling a cavity (22B, 64) behind the opening with a fugitive support material (34, 52, 54, 68) to support a filler powder (36) across the opening; traversing an energy beam (42) across the filler powder to form a deposit (44) that spans and closes the opening; in which the deposit is fused to the edges (32, 62) of the opening. The filler powder includes at least metal, and may further include flux. The support material may include filler powder, a solid (54), a foam (52) insert, a flux powder (34) and / or other ceramic powder (68). Supporting powder may have a mesh size smaller than that of the filler powder.

The invention discloses a 3D printing manufacturing method for a large-size part, which comprises the following steps: a) cutting a model of a to-be-manufactured large-size part into a plurality of sub-part models in a preset size scope; b) manufacturing and finishing the processing and forming of all sub-parts by adding materials on the basis of the sub-part models; c) jointing and fixing all the sub-parts, thereby forming the large-size part. According to the invention, the 3D printing device in insufficient effective processing size can be used for manufacturing the large-size part, the property and the whole size precision of the large-size part after being cut and spliced can be ensured, and a quick and efficient solution is supplied to the manufacturing of the sample or end product of the large-size parts in various fields.

The present invention is a medical device for controlling the release of an active agent. The medical device has a supporting structure having a porous body disposed therein. At least one elution rate controlling matrix containing an effective amount of at least one active agent is disposed within the pores of the porous body in a manner that protects the matrix from mechanical damage. The medical device may therefore be used for controlled drug release applications. Additionally, the present invention discloses a method for using the medical device for the treatment and prevention of diseases in mammals. This invention further relates to a method for using the medical device for treating and preventing vascular diseases.

An electric submersible pump and pump system including additively manufactures structures and method of manufacture are disclosed. The pump system including the electric submersible pump and an electric motor configured to operate the electric submersible pump. The electric submersible pump including a housing, at least one impeller and at least one diffuser disposed within the housing in cooperative engagement. The housing, the at least one impeller, and the at least one diffuser defining an internal volume configured to receive a fluid. At least one of the at least one impeller and the at least one diffuser configured as a monolithic additively manufactured structure comprised of a metal matrix composite. Also provided is an electric submersible pump including an impeller and a diffuser, wherein at least one of the impeller and the diffuser is configured as a monolithic additively manufactured structure comprised of a tungsten carbide (WC) dispersed in a metal matrix.

An exemplary atomizer includes a housing, a conductive part at an end of the housing, a mouthpiece with an air outlet, a liquid chamber, and at least one heating element. The liquid chamber is in the housing and configured for storing tobacco liquid. The at least one heating element is electrically connected to the conductive part. The heating element includes a liquid carrier and a heating part integrally formed with the liquid carrier. The liquid carrier has a micro porous structure. The liquid carrier is in contact with the tobacco liquid. The liquid carrier is configured for absorbing the tobacco liquid, and the heating part is configured for heating the tobacco liquid to form aerosol.

This invention relates to methods in which a protective material (44) is introduced into a metallic component, or is used to block a hole (48) in the metallic component, a filler material (34) is pre-placed or directed to an external surface of the metallic component, the filler material is heated with at least one energy beam (40) to melt or sinter a metal powder (36) contained in the filler material to form a cladding layer (16), and the protective material is removed from the metallic component, such that the protective material contains, or generates upon being heated, a protective substance. The present invention also relates to preforms (72) containing an upper section (74) containing a powdered metal (36) and a flux (38), and a lower section (76) containing a protective material (78), such that the protective material contains, or generates upon being heated, a protective substance.

The invention discloses a method and equipment of sealed chamber atmosphere deoxygenization and circulating purification for a metal 3D printer. A gas inlet and a gas outlet are respectively formed in two ends of a forming chamber; the gas inlet and the gas outlet are mutually connected through a gas circulating pipeline; a first pneumatic butterfly valve, a dust purifier, a second pneumatic butterfly valve and a water removal drier are arranged on the gas circulating pipeline; a branch pipeline is arranged on the gas circulating pipeline between the second pneumatic butterfly valve and the water removal drier; the tail end of the branch pipeline is connected with a vacuum pump; a molecular sieve and a vacuum pipeline solenoid valve are arranged on the branch pipeline; the forming chamber is connected with an inert gas source. According to the method, firstly the oxygen content in the forming chamber is reduced to a required range before machining, and gas circulating purification is started during machining, so that gas purity degree in the forming chamber is kept; pressure detection and oxygen content detection are introduced, so that the oxygen content and pressure are within a reasonable range at all time during machining. The method and the equipment improve the forming efficiency and quality of the 3D printer, and guarantee the safety and the reliability of the machining process.

A method of manufacturing an orthopedic implant is provided. The method includes creating a 3D model of an orthopedic implant having a solid portion and a porous portion and selectively adjusting a physical property of at least one of porosity of the porous portion, lattice thickness of the porous portion, beam profile of the porous portion, and topography of the 3D model. The entire implant is then additively manufactured based on the 3D model.

The invention belongs to the technical field of high-temperature alloy near net shape forming and discloses a method for preparing oxide dispersion strengthened alloy by rapid forming. The method includes: using the mechanical alloying process to obtain oxide dispersion strengthened alloy powder, using CAD (computer-aided design) software to design a three-dimensional solid model of an ODS (oxide dispersion strengthened) alloy part, subjecting the three-dimensional model to layering and slicing to disperse the three-dimensional model into a series of two-dimensional layers, smelting the ODS alloy powder layer by layer according to slicing information to obtain a laser rapidly formed blank in a needed shape, eliminating residue pores in the laser rapidly formed blank by means of hot isostatic pressing, and optimizing structure property by means of subsequent annealing or solid solution and aging heat treatment to obtain an ODS alloy part in a complex shape. Wrap packaging or fixture moulds are not needed, the complexity of shapes of parts is unlimited, and alloy components and structures are easy to control. The prepared ODS alloy is small in oxide dispersed phase, and products are high in compactness and excellent in comprehensive mechanical property.

A zirconium alloy with a coating layer formed on a surface comprising a mixed layer, the mixed layer comprises one or more very high temperature oxidation resistant material and zirconium alloy parent material selected from the group consisting of Y2O3, SiO2, ZrO2, Cr2O3, Al2O3, Cr3C2, SiC, ZrC, ZrN, Si and Cr, and in a vertical direction on a boundary between the mixed layer and the zirconium alloy parent material is formed a gradient of compositions between the very high temperature oxidation resistance material and the zirconium alloy parent material.

A method for repairing an ex-service gas turbine component (10) includes the steps of: removing a damaged section (13) from the gas turbine component (10), manufacturing a 3-D article, which fits in the gas turbine component (10) to replace the removed damaged section (13), and joining the gas turbine component (10) and the 3-D article inserted therein. Reduced cost, improved flexibility and productivity, and simplified handling are achieved by removing the damaged section (13) in the form of a cut-out section along a split line (14) as one single cut-out piece (15), measuring the cut-out piece (15) to obtain the actual non-parametric geometry data set of the cut-out piece (15), and manufacturing the 3-D article based on the geometry data set of the cut-out piece (15).

Unitary heat exchangers having integrally-formed compliant heat exchanger tubes and heat exchange systems including the same are provided. The unitary heat exchanger comprises an inlet plenum and an outlet plenum and a plurality of integrally-formed compliant heat exchanger tubes. The plurality of integrally-formed compliant heat exchanger tubes extend between and are integral with the inlet and outlet plenums to define a heat exchanger first flow passage. Each integrally-formed compliant heat exchanger tube comprises a tubular member and a plurality of integral heat transfer fins extend radially outwardly from at least one portion of the tubular member. The tubular member has a proximal tube end and a distal tube end and comprises a tubular wall having an outer wall surface and an inner wall surface.

A method for producing a 3D print fastening piece of a three-layer structure from inside to outside comprises the specific steps that computer modeling and layer-by-layer cutting are carried out; graphs are converted to light beams carrying graph information, a photosensitive drum is charged to obtain electric potential, and an electrostatic latent image is formed through light beam scanning; the electrostatic latent image passes through a magnetic brush and attracts powder to from an internal component, the surface of the internal component is processed, the steps are executed repeatedly to print the intermediate layer and the outer layer, and the surfaces of the intermediate layer and the outer layer are processed. The 3D print fastening piece made through the method has the advantages of being high in manufacturing precision, long in service life, and good in performance.

Refractory metal products, such as tantalum, can be rejuvenated after metal consumption in selected zones by filling the zones with powder and simultaneously applying focused radiant energy to the powder.

Additive manufacturing techniques may be utilized to construct effusion plates. Such additive manufacturing techniques may include defining a configuration for an effusion plate having one or more internal cooling channels. The manufacturing techniques may further include depositing a powder into a chamber, applying an energy source to the deposited powder, and consolidating the powder into a cross-sectional shape corresponding to the defined configuration. Such methods may be implemented to construct an effusion plate having one or more channels with a curved cross-sectional geometry.

A method for manufacturing a downhole tool includes obtaining a three-dimensional model of the downhole tool; converting the three-dimensional model of the downhole tool into a model having a plurality of two-dimensional layers; and building the downhole tool, layer-by-layer, by melting a metal powder or an alloy powder using an electron beam based on the model having a plurality of two-dimensional layers. A downhole tool manufactured by a process includes obtaining a three-dimensional model of the downhole tool; converting the three-dimensional model of the downhole tool into a model having a plurality of two-dimensional layers; and building the downhole tool, layer-by-layer, by melting a metal powder or an alloy powder using an electron beam based on the model having a plurality of two-dimensional layers.

A method for producing porous materials which comprises directing a plasma stream containing particles of a base material in liquid or solid / liquid form onto a substrate under controlled conditions in which the particles spot weld to the substrate or to one another without full fusion, and establishing relative movement between the plasma stream and the substrate whereby the material is deposited as a porous structure of desired porosity and shape.

A hollow blade for a turbomachine comprises an airfoil portion; the airfoil portion extends longitudinally for a length; the airfoil portion is defined laterally by an external surface; the airfoil portion has at least one internal cavity extending along said length and defined laterally by an internal surface; the airfoil portion has a set of channels extending from the external surface to the internal surface; the openings of said channels on said external surface are aligned along a curved line that reflects an isobar on said external surface.

The invention discloses metal base ceramic phase reinforced alloy tool steel powder for 3D printing. The alloy tool steel powder is characterized by comprising the following elements in percentage by mass: 0.2-5% of C, 0.2-1% of Si, 0.1-1% of Mn, 0.3-1% of Ni, 3-25% of Cr, 0.2-15% of Mo, 0.2-14.5% of V, 0.3-15% of W, 1-18% of Co, 0.2-1% of Nb, 0.2-8% of metal base ceramic phase metal elements, and the balance of iron. The invention designs a ceramic phase reinforced alloy tool steel powder material; and the component design of the material embodies better hardness, wear resistance and high-temperature performance of the material.