Molds including 3D printed components can be used to cast objects. A model of the object can be separated into multiple components, with each component not having non-printable overhang structures, thus allowing the components to be directly printed without support structures. Shell models and shell molds, e.g., molds with hollow interior, can be used for cost effectiveness. The surface of the printed object can be smoothened, for example, by solvent vapor (such as acetone for plastic), by sanding, or by a smooth coating. The object can be combinatorially cast.

A sintered bearing includes a cylindrical portion, one-side increased-diameter portion and another-side increased-diameter portion. A metal structure of the another-side increased-diameter portion has a higher density than a metal structure of a core portion of the sintered compact. A metal structure of the cylindrical portion has an expansion along a direction of ironing by the sizing core and a higher density than the metal structure of the another-side increased-diameter portion. A metal structure of the one-side increased-diameter portion has an expansion along a direction of ironing by the sizing core and a higher density than the metal structure of the cylindrical portion.

A sintered bearing includes a cylindrical portion, one-side increased-diameter portion and another-side increased-diameter portion. A metal structure of the another-side increased-diameter portion has a higher density than a metal structure of a core portion of the sintered compact. A metal structure of the cylindrical portion has an expansion along a direction of ironing by the sizing core and a higher density than the metal structure of the another-side increased-diameter portion. A metal structure of the one-side increased-diameter portion has an expansion along a direction of ironing by the sizing core and a higher density than the metal structure of the cylindrical portion.

A method of manufacturing a door hinge, which can improve productivity by applying both metal injection molding and additive manufacturing is disclosed. The door hinge includes: a first body configured to include at least one first connection member in which a first pinhole is formed; a second body configured to include at least one second connection member in which a second pinhole communicating with the first pinhole is formed; and a pin member configured to be added and filled in a cavity formed by communicating the first pinhole of the first body and the second pinhole of the second body with each other so that the first body and the second body are foldably connected to each other.

Flaky magnetic metal particles of embodiments each have a flat surface and a magnetic metal phase containing iron (Fe), cobalt (Co), and silicon (Si). An amount of Co is from 0.001 at % to 80 at % with respect to the total amount of Fe and Co. An amount of Si is from 0.001 at % to 30 at % with respect to the total amount of the magnetic metal phase. The flaky magnetic metal particles have an average thickness of from 10 nm to 100 m. An average value of the ratio of the average length in the flat surface with respect to a thickness in each of the flaky magnetic metal particles is from 5 to 10,000. The flaky magnetic metal particles have the difference in coercivity on the basis of direction within the flat surface.

A manufacturing method for a three-dimensional molded object includes repeating formation of a material layer and formation of a solidified layer, the material layer being formed by spreading a metal material on a base plate and the solidified layer being formed by irradiating the material layer with a laser beam or an electron beam, thereby molding a solidified body which is a laminated solidified layer on the base plate; and subjecting the base plate and the solidified body after molding to a heat treatment.

Methods, systems, and devices for precision locating additively manufactured components for assembly and/or post processing manufacturing are provided for herein. In some embodiments, at least one component can be additively manufactured to include one or more kinematic features on one or more surfaces of the component. The kinematic feature(s) can be configured to engage complementary kinematic feature(s) formed in a second component so the two components can form an assembly. Alternatively, the kinematic feature(s) can be configured to engage complementary kinematic feature(s) associated with a post-processing machine such that the one or more post-processing actions can be performed on the component after the component is precisely located with respect to the machine by way of the kinematic features of the component and associated with the machine. A variety of systems and methods that utilize kinematic features are also provided.

Methods, systems, and devices for precision locating additively manufactured components for assembly and/or post processing manufacturing are provided for herein. In some embodiments, at least one component can be additively manufactured to include one or more kinematic features on one or more surfaces of the component. The kinematic feature(s) can be configured to engage complementary kinematic feature(s) formed in a second component so the two components can form an assembly. Alternatively, the kinematic feature(s) can be configured to engage complementary kinematic feature(s) associated with a post-processing machine such that the one or more post-processing actions can be performed on the component after the component is precisely located with respect to the machine by way of the kinematic features of the component and associated with the machine. A variety of systems and methods that utilize kinematic features are also provided.

In an embodiment, an article comprises a plurality of structural units, wherein each structural unit comprises a first portion; a second portion; wherein the second portion contacts the first portion; and a third portion; wherein the third portion is in communication with the first portion and the second portion and is more compressible than the first portion and the second portion; wherein the first portion comprises a first shape memory alloy having a first preset state and wherein the second portion comprises a second shape memory alloy that has a second preset state; wherein the second preset state is different from the first preset state.

In an embodiment, an article comprises a plurality of structural units, wherein each structural unit comprises a first portion; a second portion; wherein the second portion contacts the first portion; and a third portion; wherein the third portion is in communication with the first portion and the second portion and is more compressible than the first portion and the second portion; wherein the first portion comprises a first shape memory alloy having a first preset state and wherein the second portion comprises a second shape memory alloy that has a second preset state; wherein the second preset state is different from the first preset state.