A composite member includes: a substrate formed of a composite material containing a plurality of diamond grains and a metal phase; and a coating layer made of metal. The surface of the substrate includes a surface of the metal phase, and a protrusion formed of a part of at least one diamond grain of the diamond grains and protruding from the surface of the metal phase. In a plan view, the coating layer includes a metal coating portion, and a grain coating portion. A ratio of a thickness of the grain coating portion to a thickness of the metal coating portion is equal to or less than 0.80. The coating layer has a surface roughness as an arithmetic mean roughness Ra of less than 2.0 μm.

Exemplified microscale selective laser sintering (μ-SLS or micro-SLS) systems and methods facilitate modeling of the nanoparticle powder bed by simulating the interactions between particles during the powder spreading operation. In particular, the exemplified methods and system use multiscale modeling techniques to accurately predict the formation and mechanical/electrical properties of parts produced by selective laser sintering of powder beds. Discrete element modeling is used for nanoscale particle interactions by implementing the different forces dominant at nanoscale. A heat transfer analysis is used to predict the sintering of individual particles in the powder beds in order to build up a complete structural model of the parts that are being produced by the SLS process.

Methods for laser additive manufacture are disclosed in which a plurality of powder layers (48, 50 and 52) are delivered onto a working surface (54A) to form a multi-powder deposit containing at least two adjacent powders layers in contact, and then applying a first laser energy (74) to a first powder layer (48) and a second laser energy (76) to a second powder layer (52) to form a section plane of a multi-material component. The multi-powder deposit may include a flux composition that provides at least one protective feature. The shapes, intensities and trajectories of the first and second laser energies may be independently controlled such that their widths are less than or equal to widths of the first and second powder layers, their intensities are tailored to the compositions of the powder layers, and their scan paths define the final shape of the multi-material component.

Methods for laser additive manufacture are disclosed in which a plurality of powder layers (48, 50 and 52) are delivered onto a working surface (54A) to form a multi-powder deposit containing at least two adjacent powders layers in contact, and then applying a first laser energy (74) to a first powder layer (48) and a second laser energy (76) to a second powder layer (52) to form a section plane of a multi-material component. The multi-powder deposit may include a flux composition that provides at least one protective feature. The shapes, intensities and trajectories of the first and second laser energies may be independently controlled such that their widths are less than or equal to widths of the first and second powder layers, their intensities are tailored to the compositions of the powder layers, and their scan paths define the final shape of the multi-material component.

A method for the manufacture of a component of defined geometry from two or more materials using a powder bed ALM process includes providing a bed of a first powdered material, selectively fusing portions of the first powdered material to build up a first three dimensional portion of the component geometry and fusing a powder containment bund from the first material to contain unfused first powdered material. A bed of a second powdered material is deposited onto the powder containment bund and selectively fused to build up a second three dimensional portion of the component geometry. Unfused first powdered material can subsequently be removed from a first side of the bund and unfused second powder from a second side of the bund. Remaining parts of the bund which do not form part of the defined geometry of the component can be removed to provide the net shape component.

A method for the manufacture of a component of defined geometry from two or more materials using a powder bed ALM process includes providing a bed of a first powdered material, selectively fusing portions of the first powdered material to build up a first three dimensional portion of the component geometry and fusing a powder containment bund from the first material to contain unfused first powdered material. A bed of a second powdered material is deposited onto the powder containment bund and selectively fused to build up a second three dimensional portion of the component geometry. Unfused first powdered material can subsequently be removed from a first side of the bund and unfused second powder from a second side of the bund. Remaining parts of the bund which do not form part of the defined geometry of the component can be removed to provide the net shape component.

A structural spacecraft component comprising internal microstructure; wherein said microstructure comprises a plurality of parallel layers and a plurality of spacers that connect adjacent parallel layers; wherein said structural spacecraft component is a product of an additive manufacturing process.

A structural spacecraft component comprising internal microstructure; wherein said microstructure comprises a plurality of parallel layers and a plurality of spacers that connect adjacent parallel layers; wherein said structural spacecraft component is a product of an additive manufacturing process.

A method of making a component of an electric machine using an additive manufacturing process is disclosed. The method includes forming a first lamina of a conductive material, building a first layer of a second material on a first surface of the first lamina, treating the second material on the first surface of the first lamina to define a first insulative layer, and building on the first insulative layer a second lamina of a conductive material. The steps can be repeated iteratively until a desired thickness or number of layers is reached.

The present disclosure provides an aluminum alloy to be used in laminate molding containing Si, Fe, Mn and inevitable impurities, in which α-phase Al—Si—Fe intermetallic compound is present in the aluminum alloy. In addition, a manufacturing method of a laminated molding is provided which laminate molds using powder of this aluminum alloy. Further, a laminate molding of this aluminum alloy is provided.