A process for forming a single crystal superalloy wave spring is provided. In one embodiment, the process may include machining a wave spring from a single crystal superalloy slab after optimizing its orientation using diffraction techniques so that the wave spring will exhibit optimal spring properties.

A method of manufacturing a punch, such as a socket punch, using wire EDM with at least six steps. The method involves forming a blank, holding the blank with an adapter, machining grooves in the blank, manufacturing a side relief of a working portion using wire EDM, milling the working portion to a final size, and forming a cone point on the end of the working portion. The method allows the punch to be manufactured more quickly and from a CAD model, therefore removing the need for over-specialized equipment and improving manufacturing times.

A method of sampling a multi-layered material and a micro-sampling tool are described. The sampling method includes penetrating a top surface of a material in a component of interest with a micro-cutting tool to a predetermined depth sufficient to include each layer of the multi-layered material and a portion of the base, without cutting through the full depth of the base, under-cutting from the depth of penetration through the base to define a micro-sample of the multi-layered material, and removing the micro-sample with each layer of the multi-layered material intact. The micro-sampler includes a cutting tool calibrated to cut to a depth no greater than 2 mm, and in some aspects, no greater than 200 microns into a multi-layered material, the material having a top surface and a metallic or ceramic base and a container for removing and storing a micro-sample cut from the material with each layer of the multi-layered material and a portion of the base intact.

An additive manufacturing support device includes reading circuitry that reads shaped article data that is data indicating the three-dimensional shape of a shaped article, first generating circuitry that generates primary data that is data indicating the three-dimensional shape of a primary separated portion provided in a region where a cutting part of a cutting apparatus passes between the plate and the shaped article, and second generating circuitry that generates, based on a machining allowance between the cutting part and an object to be cut in a process in which the cutting part passes between the plate and the shaped article, secondary data for reducing change in the machining allowance.

An additive manufacturing support device includes reading circuitry that reads shaped article data that is data indicating the three-dimensional shape of a shaped article, first generating circuitry that generates primary data that is data indicating the three-dimensional shape of a primary separated portion provided in a region where a cutting part of a cutting apparatus passes between the plate and the shaped article, and second generating circuitry that generates, based on a machining allowance between the cutting part and an object to be cut in a process in which the cutting part passes between the plate and the shaped article, secondary data for reducing change in the machining allowance.

This invention is directed to a new method of mass-transfer/fabrication of micro-sized features/structures onto the inner diameter (ID) surface of a stent. This new approach is provided by technique of through mask electrical micro-machining. One embodiment discloses an application of electrical micro-machining to the ID of a stent using a customized electrode configured specifically for machining micro-sized features/structures.

This invention is directed to a new method of mass-transfer/fabrication of micro-sized features/structures onto the inner diameter (ID) surface of a stent. This new approach is provided by technique of through mask electrical micro-machining. One embodiment discloses an application of electrical micro-machining to the ID of a stent using a customized electrode configured specifically for machining micro-sized features/structures.

A method of forming a medical device contact element includes annealing an elongated rod of Ti-15Mo alloy material to form an annealed rod having a Young's Modulus of less than 13.5 Mpsi and an elastic range or strain of at least 0.7%. Then forming a contact ring element from the annealed rod and assembling the contact ring element into a medical device. Contact rings and lead receptacles including the same are also described.

A method of forming a medical device contact element includes annealing an elongated rod of Ti-15Mo alloy material to form an annealed rod having a Young's Modulus of less than 13.5 Mpsi and an elastic range or strain of at least 0.7%. Then forming a contact ring element from the annealed rod and assembling the contact ring element into a medical device. Contact rings and lead receptacles including the same are also described.

A method of manufacturing a gear, the method includes applying a first charge to a workpiece and applying a second, opposite charge to an electrochemical machining (ECM) attachment, the ECM attachment having a pattern. The method further includes simultaneously forming a plurality of surfaces of a gear tooth in the workpiece using the pattern of the ECM attachment while applying the first charge to the workpiece and applying the second charge to the ECM attachment and turning the workpiece and the ECM attachment in opposite rotational directions. The plurality of surfaces includes at least one end face and a top land of the gear tooth.