This invention relates to a method for manufacturing a part of complex shape (3) by successive deposition of layers according to a technique of 3D additive printing and pressure sintering, comprising the following steps: an initial step of producing a model (1) from a material chosen from a porous or pulverulent material based on a metal alloy, a ceramic, a composite material and a lost material by formation of successive layers deposited according to the digitally controlled 3D additive printing technique, followed by a step of introducing a preform (1) made of porous or pulverulent material to be densified, derived from the model (1), into a mold (2) filled with a sacrificial porous or pulverulent material (13) in addition to the preform (1), the uniaxial densifying pressure sintering (10) then being applied to the mold (2) in order to form the part (3) which is finally extracted from the mold (2).

Breakable three dimensional (3D) printed molds are disclosed. An example method for forming a mold having a cavity by creating a plurality of layers using an additive manufacturing process includes providing a build material; and controlling a fusion level of the build material separately for different layers of the plurality of layers to separately form the layers with a porosity corresponding to a target porosity.

Breakable three dimensional (3D) printed molds are disclosed. An example method for forming a mold having a cavity by creating a plurality of layers using an additive manufacturing process includes providing a build material; and controlling a fusion level of the build material separately for different layers of the plurality of layers to separately form the layers with a porosity corresponding to a target porosity.

An assembly for densification under load along at least one direction of compression. The assembly includes: at least one volume to be densified having a powdery and/or porous composition and having variations in thickness along the direction of compression; and at least one counter-form of a powdery and/or porous composition, having at least one face facing at least one portion of the volume. The face and each of the portions are separated by at least one deformable interface layer.

Frangible firearm projectiles, firearm cartridges containing the same, and methods for forming the same. The firearm projectiles are formed from a compacted mixture of metal powders that includes zinc and iron powders and which may include an anti-sparking agent. The compacted mixture is heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. The frangible firearm projectile may be formed by a mechanism that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does not include forming a liquid phase of any of the metal powders or utilizing a polymeric binder. A majority component of the frangible firearm projectile may be iron. One or more of zinc, bismuth, tin, copper, nickel, tungsten, boron, and/or alloys thereof may form a minority component of the frangible firearm projectile. The anti-sparking agent may include a borate, such as boric acid.

The present disclosure is directed to systems and methods for producing a metal-containing powder useful for additive manufacturing. The metal-containing powder includes a plurality of metal-containing platelets having a defined physical geometry and a defined aspect ratio. The metal platelets may be produced by depositing a metal layer on a substrate that includes one or more recessed or raised surface features. The one or more recessed or raised surface features create a fracture pattern in a metal layer deposited across at least a portion of the one or more surface features. By separating the metal layer from the substrate and fracturing the metal layer along the fracture pattern, a plurality of metal platelets are produced. In some embodiments, a release agent may be disposed between the metal layer and the substrate to facilitate the separation of the metal layer from the substrate.

The present disclosure is directed to systems and methods for producing a metal-containing powder useful for additive manufacturing. The metal-containing powder includes a plurality of metal-containing platelets having a defined physical geometry and a defined aspect ratio. The metal platelets may be produced by depositing a metal layer on a substrate that includes one or more recessed or raised surface features. The one or more recessed or raised surface features create a fracture pattern in a metal layer deposited across at least a portion of the one or more surface features. By separating the metal layer from the substrate and fracturing the metal layer along the fracture pattern, a plurality of metal platelets are produced. In some embodiments, a release agent may be disposed between the metal layer and the substrate to facilitate the separation of the metal layer from the substrate.

A method includes forming a fluid conduit inside a heat shield in an additive manufacturing process, wherein a fluid nozzle is defined at a downstream end of the fluid conduit, and wherein the heat shield is formed about the fluid nozzle. The method includes removing powder from an interior passage of the fluid conduit and fluid nozzle and from an insulation gap defined between the heat shield and the fluid conduit and fluid nozzle. The method includes separating the heat shield, fluid conduit, and fluid nozzle from the build platform. The method includes shifting the fluid conduit and fluid nozzle to a shifted position relative to the heat shield, and securing the fluid conduit and fluid nozzle to the heat shield in the shifted position.

A method includes forming a fluid conduit inside a heat shield in an additive manufacturing process, wherein a fluid nozzle is defined at a downstream end of the fluid conduit, and wherein the heat shield is formed about the fluid nozzle. The method includes removing powder from an interior passage of the fluid conduit and fluid nozzle and from an insulation gap defined between the heat shield and the fluid conduit and fluid nozzle. The method includes separating the heat shield, fluid conduit, and fluid nozzle from the build platform. The method includes shifting the fluid conduit and fluid nozzle to a shifted position relative to the heat shield, and securing the fluid conduit and fluid nozzle to the heat shield in the shifted position.

Methods and apparatuses for disassembling components are described. An apparatus in accordance with an aspect of the present disclosure comprises a first component including a first adhesive interface, a second component including a second adhesive interface, a joint between the first and second adhesive interfaces, the joint comprising an adhesive bonding to the first adhesive interface and to the second adhesive interface, such that the first component and the second component are joined together, and at least one thermal element in the adhesive, wherein the at least one thermal element is configured to weaken the joint by heating the adhesive when an energy is applied to the thermal element.