Various embodiments relate to additive manufacturing in which the Langmuir equation can be used to predict composition in the processing. This equation can be integrated into a model with knowledge of elemental solubility and relative reactivity of relevant elements in the additive manufacturing processing. Use of thermodynamic principles can be programmed into a finite element modeling strategy integrating the Langmuir equation, coupling the thermal fields of additive manufacturing and the surrounding environments with the rules and/or equations to predict solute pickup and/or solute loss. The modeling strategy can be implemented to identify the elements in relative concentrations to be used in the additive manufacturing processing to provide for the controlled loss of certain elements to prevent absorption of unwanted elements into molten material, formed by additive manufacturing, from the atmosphere around the molten material. Additional systems and methods are disclosed.

Various embodiments relate to additive manufacturing in which the Langmuir equation can be used to predict composition in the processing. This equation can be integrated into a model with knowledge of elemental solubility and relative reactivity of relevant elements in the additive manufacturing processing. Use of thermodynamic principles can be programmed into a finite element modeling strategy integrating the Langmuir equation, coupling the thermal fields of additive manufacturing and the surrounding environments with the rules and/or equations to predict solute pickup and/or solute loss. The modeling strategy can be implemented to identify the elements in relative concentrations to be used in the additive manufacturing processing to provide for the controlled loss of certain elements to prevent absorption of unwanted elements into molten material, formed by additive manufacturing, from the atmosphere around the molten material. Additional systems and methods are disclosed.

The present disclosure is related to a method to control sizes of core-shell nanoparticles comprising the steps of: manufacturing slurry by irradiating ultrasonic waves to a dispersion solution containing a reducing solvent, a carbon support, a transition metal precursor and a precious metal precursor; manufacturing a solid by filtering the manufactured slurry, followed by washing and drying; and manufacturing a nanoparticle of a transition metal core and a platinum shell by heat-treating the dried solid at a temperature of 450 to 900° C. and a pressure of 1 to 90 bar for 0.5 to 10 hours under N.sub.2 atmosphere.

Closed-loop metal powder management methods for additive manufacturing. Virgin metal powder is provided in a closed powder container comprising at least one sensor, tracker, or optical device. The metal powder is transferred to an additive manufacturing system, a portion of a metal powder layer is consolidated, and excess metal powder is transferred from the additive manufacturing system to the powder container, a second powder container, or an internal powder container. Virgin metal powder or a second metal powder are added to the excess metal powder, a quality of the mixed powder is validated, the process is repeated at least once, and powder physical transfer data associated with at least one of the steps is collected and stored in a data repository. Powder material parameters may be measured and assessed, and may be also be stored in the data repository.

Closed-loop metal powder management methods for additive manufacturing. Virgin metal powder is provided in a closed powder container comprising at least one sensor, tracker, or optical device. The metal powder is transferred to an additive manufacturing system, a portion of a metal powder layer is consolidated, and excess metal powder is transferred from the additive manufacturing system to the powder container, a second powder container, or an internal powder container. Virgin metal powder or a second metal powder are added to the excess metal powder, a quality of the mixed powder is validated, the process is repeated at least once, and powder physical transfer data associated with at least one of the steps is collected and stored in a data repository. Powder material parameters may be measured and assessed, and may be also be stored in the data repository.

3D-printed parts may include binding agents to be removed following an additive manufacturing process. A debinding process removes the binding agents by immersing the part in a solvent bath causing chemical dissolution of the binding agents. The time of exposure of the 3D-printed part to the solvent is determined based on the geometry of the part, wherein the geometry is applied to predict the diffusion of the solvent through the 3D-printed part. The 3D-printed part is then immersed in the solvent bath to remove the binding agent, and is removed from the solvent bath after the time of exposure.

3D-printed parts may include binding agents to be removed following an additive manufacturing process. A debinding process removes the binding agents by immersing the part in a solvent bath causing chemical dissolution of the binding agents. The time of exposure of the 3D-printed part to the solvent is determined based on the geometry of the part, wherein the geometry is applied to predict the diffusion of the solvent through the 3D-printed part. The 3D-printed part is then immersed in the solvent bath to remove the binding agent, and is removed from the solvent bath after the time of exposure.

Certain aspects of the technology disclosed herein include an apparatus and method for programming a crystal lattice structure of a nanoparticle. A particle programming apparatus can include an input channel connected a particle sampling system. The particle sampling system can direct freshly milled nanoparticles to the particle programming apparatus if the nanoparticles are determined to be below a threshold size. The particle programming apparatus can include one or more programming devices configured to alter a crystal lattice of the received nanoparticles including an ultrasonic sound generator, a magnetic pulse generator, and a voltage generator. The one or more programming devices applies any of a sound, magnetic pulse, and voltage to the received nanoparticles within a time threshold of receiving the nanoparticles from the mill core.

Certain aspects of the technology disclosed herein include an apparatus and method for programming a crystal lattice structure of a nanoparticle. A particle programming apparatus can include an input channel connected a particle sampling system. The particle sampling system can direct freshly milled nanoparticles to the particle programming apparatus if the nanoparticles are determined to be below a threshold size. The particle programming apparatus can include one or more programming devices configured to alter a crystal lattice of the received nanoparticles including an ultrasonic sound generator, a magnetic pulse generator, and a voltage generator. The one or more programming devices applies any of a sound, magnetic pulse, and voltage to the received nanoparticles within a time threshold of receiving the nanoparticles from the mill core.

Certain aspects of the technology disclosed herein include an apparatus and method for forming nanoparticles. The method includes a mechanical milling process induced by aerodynamic, centrifugal, and centripetal forces and further augmented by ultrasound, magnetic pulse, and high voltage impact. A nanoparticle mill having an atmospheric and luminance controlled environment can form precisely calibrated nanoparticles. A nanoparticle mill can include first aerodynamic vane configured to rotate around a central axis of the nanoparticle mill in a first direction, and a second aerodynamic vane configured to rotate around the central axis in a second direction. An aerodynamic shape of an aerodynamic vane can be configured to cause particles within the nanoparticle mill to flow around the aerodynamic vane. The nanoparticle mill can include a primary product line, a nanoparticle sampling line, a particle programming array, a solidifying chamber, or any combination thereof.