A protective mask for a part, the part including a plurality of openings in a surface thereof, is provided. The protective mask includes a mounting member at least partially within each of at least two of the plurality of openings. Each mounting member includes a water soluble material. A masking member couples the at least two mounting members. The masking member includes a non-water soluble material. Each mounting member includes a first plurality of integral layers of the water soluble material, and the masking member includes a second plurality of integral layers of the non-water soluble material. The protective mask can be made by a two material additive manufacturing system. A related method is also provided.

In an example of a method for three-dimensional (3D) printing, metallic build material layers are patterned to form an intermediate structure. During patterning, a binding agent is selectively applied to define: a build material support structure and a patterned intermediate part. Also during patterning, i) the binding agent and a separate agent including an etch sensitizer or ii) a combined agent including a binder and the etch sensitizer are selectively applied to define a patterned etchable connection between at least a portion of the build material support structure and at least a portion patterned intermediate part. The intermediate structure is heated.

A conforming coating mask is used with a turbine component having a plurality of cooling holes. The conforming coating mask includes at least two anchors; a plurality of radial mask strips integrally formed with and extending between each of the at least two anchors; and at least one coating mask securing insert. Each at least one coating mask securing insert integrally formed with a respective at least one radial mask strip; wherein the plurality of radial mask strips align with and cover the plurality of cooling holes.

A method for manufacturing a part by additive manufacturing including providing CAD data defining a geometry of the part, providing CAD data defining a geometry of a first clamping element, wherein the geometry of the first clamping element is determined in consideration of a geometry of a second clamping element such that the first clamping element can be clamped into the second clamping element for holding the part in a desired position for post-processing, generating machining data based on the CAD data defining the geometry of the part and the geometry of the first clamping element, and forming the part and the first clamping element by additive manufacturing process based on the machining data. The first clamping element has at least two parallel side surfaces and the second clamping element has two vice jaws positioned in parallel to each other along a longitudinal direction of the second clamping element.

A method for manufacturing a part by additive manufacturing including providing CAD data defining a geometry of the part, providing CAD data defining a geometry of a first clamping element, wherein the geometry of the first clamping element is determined in consideration of a geometry of a second clamping element such that the first clamping element can be clamped into the second clamping element for holding the part in a desired position for post-processing, generating machining data based on the CAD data defining the geometry of the part and the geometry of the first clamping element, and forming the part and the first clamping element by additive manufacturing process based on the machining data. The first clamping element has at least two parallel side surfaces and the second clamping element has two vice jaws positioned in parallel to each other along a longitudinal direction of the second clamping element.

Frangible firearm projectiles, firearm cartridges, and methods for forming the same. The projectiles are formed from metal powder and include an anti-sparking agent. One or more of iron, zinc, bismuth, tin, copper, nickel, tungsten, boron, and/or alloys thereof may form the metal powder. The projectiles may be formed from a compacted mixture of two or more different metal powders. The anti-sparking agent may include a borate, such as boric acid, zinc chloride, and/or petrolatum. The anti-sparking agent may be dispersed within, and/or applied as a coating on, the exterior of the projectile. The compacted mixture may be heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. Such domains may be formed by a mechanism that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does form a liquid phase of the metal powder or utilize a polymeric binder.

Embodiments of the disclosure provide a test article for additive manufacture and related methods. A test article formed may include a body having a forward face and a rearward face horizontally opposite the forward face. A first surface extending between the forward face and the rearward face of the body may include a plurality of protrusions for removable coupling of the body to a build plate. A second surface on the body may extend between the forward face and the rearward face of the body, and may include a plurality of angled flat surface portions. Each of the plurality of angled flat surface portions may have a distinct angle with respect to a horizontal plane of the body. An angular difference between each adjacent angled flat surface portion in the plurality of angled flat surface portions is substantially uniform.

An article of manufacture includes a part structure formed via a first additive manufacturing process and a floating structure within the part structure which is mechanically decoupled from the part structure. The floating structure is formed concurrently with the part structure via the first additive manufacturing process.

An article of manufacture includes a part structure formed via a first additive manufacturing process and a floating structure within the part structure which is mechanically decoupled from the part structure. The floating structure is formed concurrently with the part structure via the first additive manufacturing process.

An apparatus is disclosed to create a breakaway junction for 3D printed parts. Powder is spread along a target zone, such as a build bed. A liquid functional agent is selectively dispensed upon the powder to form a 3D object, a supporting part, and the breakaway junction between them.