A method of creating a functionally-graded multi-material (FGM) part in multi-material additive manufacturing includes providing a part digitized into voxels, generating a lattice structure having a series of repeating unit cells, where each is the smallest nonrepeating constituent of the lattice structure and is generated by a continuous surface defined by a continuous function. The method further includes taking an inverse volume of the lattice structure within the part, creating a material gradient by varying a thickness of the surface at the boundary between the lattice structure and the inverse volume, assigning one of the two FGM component materials to the voxels in the volume occupied by the lattice structure and assigning the other to the voxels occupied by the inverse volume, outputting the voxels each with a designated material, the lattice structure and the inverse volume forming a mechanical interlock at the interface of the two component materials.

A method of creating a functionally-graded multi-material (FGM) part in multi-material additive manufacturing includes providing a part digitized into voxels, generating a lattice structure having a series of repeating unit cells, where each is the smallest nonrepeating constituent of the lattice structure and is generated by a continuous surface defined by a continuous function. The method further includes taking an inverse volume of the lattice structure within the part, creating a material gradient by varying a thickness of the surface at the boundary between the lattice structure and the inverse volume, assigning one of the two FGM component materials to the voxels in the volume occupied by the lattice structure and assigning the other to the voxels occupied by the inverse volume, outputting the voxels each with a designated material, the lattice structure and the inverse volume forming a mechanical interlock at the interface of the two component materials.

A powder feeding device includes: a hopper including a discharge port for discharging powder; and a conveyance device configured to move a conveyance surface disposed below the discharge port in a first direction and invert the conveyance surface in a front end portion. The hopper includes a front wall portion positioned on a downstream side of the discharge port in the first direction. A predetermined gap is formed between a lower end of the front wall portion and the conveyance surface. In the powder feeding device, powder deposited on the conveyance surface is conveyed in the first direction by the conveyance device with a thickness corresponding to the gap and dropped from the front end portion.

A powder feeding device includes: a hopper including a discharge port for discharging powder; and a conveyance device configured to move a conveyance surface disposed below the discharge port in a first direction and invert the conveyance surface in a front end portion. The hopper includes a front wall portion positioned on a downstream side of the discharge port in the first direction. A predetermined gap is formed between a lower end of the front wall portion and the conveyance surface. In the powder feeding device, powder deposited on the conveyance surface is conveyed in the first direction by the conveyance device with a thickness corresponding to the gap and dropped from the front end portion.

A hybrid method of surface hardening metallic components using a combination of chemical modification achieved through additive manufacturing and/or diffusion-based processing with transformation-based processing using a high energy density heat source. The hybrid process results in increased surface hardness and/or increased average case hardness and/or increased case depth compared to either treatment individually.

A hybrid method of surface hardening metallic components using a combination of chemical modification achieved through additive manufacturing and/or diffusion-based processing with transformation-based processing using a high energy density heat source. The hybrid process results in increased surface hardness and/or increased average case hardness and/or increased case depth compared to either treatment individually.

A method of forming an implant having a porous tissue ingrowth structure and a bearing support structure. The method includes depositing a first layer of a metal powder onto a substrate, scanning a laser beam over the powder so as to sinter the metal powder at predetermined locations, depositing at least one layer of the metal powder onto the first layer and repeating the scanning of the laser beam.

A method of forming an implant having a porous tissue ingrowth structure and a bearing support structure. The method includes depositing a first layer of a metal powder onto a substrate, scanning a laser beam over the powder so as to sinter the metal powder at predetermined locations, depositing at least one layer of the metal powder onto the first layer and repeating the scanning of the laser beam.

A three-dimensional shape data generating apparatus includes: an acquiring section that acquires element data generated by dividing a three-dimensional shape into first elements, the three-dimensional shape being modeled with a plurality of modeling materials having different resolutions, each first element corresponding to a resolution of a first modeling material among the plurality of modeling materials; a dividing section that divides the three-dimensional shape into second elements, each second element corresponding to a second modeling material having a resolution lower than the resolution of the first modeling material and having a size larger than the first element; and a generating section that generates three-dimensional shape data through setting modeling materials for the first and second elements, respectively, according to the number of the first elements covered by the second element.

A three-dimensional shape data generating apparatus includes: an acquiring section that acquires element data generated by dividing a three-dimensional shape into first elements, the three-dimensional shape being modeled with a plurality of modeling materials having different resolutions, each first element corresponding to a resolution of a first modeling material among the plurality of modeling materials; a dividing section that divides the three-dimensional shape into second elements, each second element corresponding to a second modeling material having a resolution lower than the resolution of the first modeling material and having a size larger than the first element; and a generating section that generates three-dimensional shape data through setting modeling materials for the first and second elements, respectively, according to the number of the first elements covered by the second element.