A 3D printed tool includes a tool body extending between first and second ends and including at least one loading surface defining an axis, at least one support surface configured to receive a clamp, and a structural weakness portion positioned along the axis between the at least one loading surface and the at least one support surface. The structural weakness portion is configured to cause the at least one tool body to fail along a predetermined fault line such that the at least one tool body splits substantially down a middle of the at least one tool body when overloaded.

A 3D printed tool includes a tool body extending between first and second ends and including at least one loading surface defining an axis, at least one support surface configured to receive a clamp, and a structural weakness portion positioned along the axis between the at least one loading surface and the at least one support surface. The structural weakness portion is configured to cause the at least one tool body to fail along a predetermined fault line such that the at least one tool body splits substantially down a middle of the at least one tool body when overloaded.

A method for forming a reinforced metallic structure includes providing a tool having a formation surface corresponding to a desired structure shape of the reinforced metallic structure. The method also includes positioning a plurality of fibers on the formation surface of the tool. The method also includes depositing a layer of material on the plurality of fibers using a cold-spray technique. The method also includes removing the layer of material with the plurality of fibers from the tool to create the reinforced metallic structure.

A method of providing an abrasive structure for additive manufacturing includes determining of a design of a portion of a powdery base material and selectively solidifying the portion in a bed of the base material according to the determined design such that an abrasive structure is generated, wherein the abrasive structure is still movable in the bed of the base material. Further, an additively manufactured component has an internal surface with a surface roughness of less than 100 μm, preferably less than 60 μm.

A method of providing an abrasive structure for additive manufacturing includes determining of a design of a portion of a powdery base material and selectively solidifying the portion in a bed of the base material according to the determined design such that an abrasive structure is generated, wherein the abrasive structure is still movable in the bed of the base material. Further, an additively manufactured component has an internal surface with a surface roughness of less than 100 μm, preferably less than 60 μm.

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.

A connecting rod comprises a shaft connecting a first end including a first bore with a second end including a second bore. Methods for forming and assembling a connecting rod and crankshaft assembly include fabricating the second end of the connecting rod via additive manufacturing such that the second end comprises a first and second weakened regions on opposing sides of the second bore, and breaking the second end of the connecting rod at the first and second weakened regions to form a connecting rod assembly comprising a second end base and a second end cap, wherein the base comprises a first fracture face and a second fracture face which each respectively correspond to a first fracture face and a second fracture face of the cap. The methods can further include mating the base and the cap such that a crankpin of a crankshaft is disposed within the second bore.

A connecting rod comprises a shaft connecting a first end including a first bore with a second end including a second bore. Methods for forming and assembling a connecting rod and crankshaft assembly include fabricating the second end of the connecting rod via additive manufacturing such that the second end comprises a first and second weakened regions on opposing sides of the second bore, and breaking the second end of the connecting rod at the first and second weakened regions to form a connecting rod assembly comprising a second end base and a second end cap, wherein the base comprises a first fracture face and a second fracture face which each respectively correspond to a first fracture face and a second fracture face of the cap. The methods can further include mating the base and the cap such that a crankpin of a crankshaft is disposed within the second bore.

A method for manufacturing parts or devices using additive manufacturing is provided. The method forms the parts or devices, and also forms a transition layer or transition layers of partially or incompletely sintered powder between a build-plate and/or supports provided on the build-plate, and/or a gap or gaps of unsintered powder, or partially or incompletely sintered powder between the supports and the parts. The transition layer(s) and the gap(s) facilitate separation of the parts or devices from the build-plate or the supports provided on the build-plate.