Systems and methods for generating graded lattice structures that can be used as infill for additively manufactured articles. Tailored sectioning and field-based smoothing are modified polygon, e.g., circle, packing algorithms that adjust the size of the circles based on physical field data to adapt the infill generation process to a field expected to be experienced by the article. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from tailored sectioning, field-based smoothing, and force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.

Disclosed herein is an additive manufacturing system that includes an energy source, a powder supply, and a build chamber. The build chamber includes a base plate and two or more variable build plates coupled to the base plate. The two or more variable build plates each have one or more adjustable features. The two or more variable build plates are configurable to position two or more parts at different heights relative to a top level of the build chamber. The additive manufacturing system also includes a control system configured to control the energy source to fuse material from the powder supply to at least one of the two or more parts while the two or more parts are respectively positioned by the two or more variable build plates at different heights relative to the top level of the build chamber.

A method for manufacturing an aeronautical part utilizes injection molding. After injecting the prepared mixtures to obtain two green blanks, an assembly area of at least one of these two blanks is heated. The blanks are assembled and then debinding is carried out. A sintering treatment is then carried out.

A method for manufacturing an aeronautical part utilizes injection molding. After injecting the prepared mixtures to obtain two green blanks, an assembly area of at least one of these two blanks is heated. The blanks are assembled and then debinding is carried out. A sintering treatment is then carried out.

A method of manufacturing a metal member including a first part and a second part includes a first fabrication process of fabricating the first part through a three-dimensional metal stack fabrication by a powder bed method, and a second fabrication process of fabricating an outer circumference of the second part through the three-dimensional metal stack fabrication by the powder bed method, and then sintering metallic powder remaining in an inner portion of the second part by hot isostatic pressing so as to fabricate the second part.

A method of manufacturing a metal member including a first part and a second part includes a first fabrication process of fabricating the first part through a three-dimensional metal stack fabrication by a powder bed method, and a second fabrication process of fabricating an outer circumference of the second part through the three-dimensional metal stack fabrication by the powder bed method, and then sintering metallic powder remaining in an inner portion of the second part by hot isostatic pressing so as to fabricate the second part.

A method for fabricating a vane for a variable geometry turbocharger (VGT) includes the steps of providing or obtaining a substrate metal in powdered form, mixing a binder with the powdered substrate metal to form a mixture, performing an injection molding process using the mixture to form a green substrate in the shape of the vane, debinding the green substrate to form a brown substrate in the shape of the vane having a porous structure, applying a surface treatment slurry to at least a portion of the brown substrate, and sintering the surface treated brown substrate to form the vane.

A method for prefabricating a poor fusion defect by controlling a LMD process, including: obtaining a model, with a shaping zone and a defect prefabricated zone that has a preset defect; and performing a layerwise slicing process on the model. For each deposition layer of the defect prefabricated zone, the preset defect has a maximum dimension a0 in a perpendicular direction; for the shaping zone, performing a shaping process under predetermined shaping process parameters of the LMD process; and for the defect prefabricated zone, controlling shaping process parameters as follows: when a0<D, with respect to the shaping zone, changing a scan pitch between shaping paths and a powder feed rate in the deposition layer, thereby prefabricating the poor fusion defect; and when a0≥D, with respect to the shaping zone.

Turbomachine hollow blade (11) comprising at least one vane (14) having lateral walls (15) which are intended to guide a flow in a flow path around the vane and which are fixed to a first platform (12) at a first longitudinal end of the vane (14), the vane (14) further comprising an internal cavity between the lateral walls (15), which cavity is intended for passing a vane-cooling fluid, with a fluid inlet opening (19) opening through said first platform (12), characterized in that a gyroid surface network (18) fills at least part of the cavity, being arranged therein so as to guide the cooling fluid, and is in contact with at least part of the lateral walls (15).

An additively manufactured (AM) object may include a body including an opening in an exterior surface thereof, the opening having a shape and a first area at the exterior surface of the body. A mask may be positioned over the opening. The mask has the shape of the opening and a second area that is larger than the first area so as to overhang the exterior surface of the body about the opening. A plurality of support ligaments couple to the mask and the exterior surface of the body at a location adjacent to the opening to support a portion of the mask. A coating can be applied to the object, and the mask removed. The final AM object includes a plurality of ligament elements extending from the exterior surface of the body and through the coating adjacent the opening, each ligament element at least partially surrounded by the coating.