A powder cleaning system can include a fluidized bed reactor configured to retain powder and fluidize the powder to remove adsorbate and/or other contaminants from the powder, at least one inlet line, and one or more gas sources configured to be in selective fluid communication with the fluidized bed reactor via the at least one inlet line to selectively provide an inlet flow having one or more gases to the fluidized bed reactor to fluidize the powder with the one or more gases within the fluidized bed reactor. The system can include at least one outlet line in fluid communication with the fluidized bed reactor and configured to allow removal of outlet flow which comprises the adsorbate and/or other contaminants from the fluidized bed reactor.

A method of preparation of titanium and titanium alloy powder for 3D printing is based on a fluidized bed jet milling technique. Hydride-dehydrate titanium powder and titanium alloy powder are used as main raw material powder, jet milling and shaping are carried out in shielding atmosphere of nitrogen or argon, and finally high-performance titanium and titanium alloy powder meeting the requirements of 3D printing process is obtained. The titanium and titanium alloy powder prepared using this method has a narrow particle size distribution, approximately spherical shape, and controllable oxygen content.

A method of preparation of titanium and titanium alloy powder for 3D printing is based on a fluidized bed jet milling technique. Hydride-dehydrate titanium powder and titanium alloy powder are used as main raw material powder, jet milling and shaping are carried out in shielding atmosphere of nitrogen or argon, and finally high-performance titanium and titanium alloy powder meeting the requirements of 3D printing process is obtained. The titanium and titanium alloy powder prepared using this method has a narrow particle size distribution, approximately spherical shape, and controllable oxygen content.

A process for forming a metal part from an additive manufacturing process with a smooth surface that includes the steps of printing the part using an AM process, heating the printed part to its solution heat treat or annealing temperature, placing the printed part in a fluidized salt bath for a short period of time to smooth a rough surface on the metal part, and then rapidly cool the heated metal part to prevent any change in grain structure. If the metal part is made from a metal material that oxidizes, then the metal part is treated in an enclosed chamber with Argon gas.

A process for forming a metal part from an additive manufacturing process with a smooth surface that includes the steps of printing the part using an AM process, heating the printed part to its solution heat treat or annealing temperature, placing the printed part in a fluidized salt bath for a short period of time to smooth a rough surface on the metal part, and then rapidly cool the heated metal part to prevent any change in grain structure. If the metal part is made from a metal material that oxidizes, then the metal part is treated in an enclosed chamber with Argon gas.

A 3D printing system comprises a pressure system to provide a negative pressure and a hopper having a first opening to receive powder to be used for printing, wherein the powder is received in an open state of the first opening. The hopper has a second opening to guide air from outside the hopper to inside the hopper and has a third opening connected to the pressure system so as to provide for a negative pressure inside the hopper, the negative pressure to overcompensate for the air receive through the second opening such that a pressure being lower when compared to an ambient pressure of the hopper is generated inside the hopper.

A 3D printing system comprises a pressure system to provide a negative pressure and a hopper having a first opening to receive powder to be used for printing, wherein the powder is received in an open state of the first opening. The hopper has a second opening to guide air from outside the hopper to inside the hopper and has a third opening connected to the pressure system so as to provide for a negative pressure inside the hopper, the negative pressure to overcompensate for the air receive through the second opening such that a pressure being lower when compared to an ambient pressure of the hopper is generated inside the hopper.

A method for the additive manufacturing of a closed-cell porous matrix is described herein. A powder-bed, additive manufacturing process is used to create a piece with partially-closed cavities filled with unfused powder. Vacuum, negative pressure, positive pressure, or solvent is used to evacuate the powder from the cavities. Finally, a fresh layer of powder is used to cover the opening of the cavity and the powder is fused on top to close the opening.

A method for the additive manufacturing of a closed-cell porous matrix is described herein. A powder-bed, additive manufacturing process is used to create a piece with partially-closed cavities filled with unfused powder. Vacuum, negative pressure, positive pressure, or solvent is used to evacuate the powder from the cavities. Finally, a fresh layer of powder is used to cover the opening of the cavity and the powder is fused on top to close the opening.

Induced material segregation methods of manufacturing a polycrystalline diamond compact (PDC) cutter result in formation of a polycrystalline diamond/tungsten carbide (WC) composite material having a smooth compositional gradient from maximum WC concentration at one face to maximum diamond concentration at another face. Because the compositional gradient is smooth, very little or no mismatch of coefficient of thermal expansion occurs, which improves a service lifetime of the PDC cutter.