A method of additive manufacture suitable for large and high resolution structures is disclosed. The method may include sequentially advancing each portion of a continuous part in the longitudinal direction from a first zone to a second zone. In the first zone, selected granules of a granular material may be amalgamated. In the second zone, unamalgamated granules of the granular material may be removed. The method may further include advancing a first portion of the continuous part from the second zone to a third zone while (1) a last portion of the continuous part is formed within the first zone and (2) the first portion is maintained in the same position in the lateral and transverse directions that the first portion occupied within the first zone and the second zone.

Additive manufacturing can involve dispensing a powdered material to form a layer of a powder bed on a support surface of a build platform. A portion of the layer of the powder bed may be selectively melted or fused to form one or more temporary walls out of the fused portion of the layer of the powder bed to contain another portion of the layer of the powder bed on the build platform

The present disclosure relates to a composite panel having a sandwich structure formed by a central core having a primary cellular structure, for example, of the honeycomb type, sandwiched between two skins. The primary cellular structure includes an array of main cells. The composite panel further includes a plurality of pins, each pin being, on the one hand, arranged to be housed and to cooperate inside a main cell and, on the other hand, formed of a secondary cellular structure having an array of secondary cells.

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved structure formation, part creation and manipulation, use of multiple additive manufacturing systems, and high throughput manufacturing methods suitable for automated or semi-automated factories are also disclosed.

An apparatus for additive printing is provided. The apparatus includes a print head, an optical-mechanical assembly, and a rejected energy handling device. The print head includes an energy source and one or more energy patterning devices configured to provide one or more two-dimensional patterned incident beams to process a powdered material. The optical-mechanical assembly includes optical components arranged to receive and direct the one or more incident beams into a location. The rejected energy handling device is configured to reuse beam energy rejected by the one or more energy patterning devices by relaying the rejected beam energy to either or both of an electricity generator and a thermal management system.

The disclosure relates to a method for producing a diffusion blocking layer including aluminum oxide on a metal plate, which consists of a base material containing at least iron (Fe) and chromium (Cr). The aluminum used for forming the aluminum oxide is contained in the base material. A layer made of titanium dioxide serves as an oxygen contributor for the oxidation of the aluminum to a-aluminum oxide. The disclosure further relates to an integration of the method into the production of an exhaust gas treatment unit, where the exhaust gas treatment unit has a honeycomb body and a housing wither of which is formed with a metal plate having a base material that contains at least iron (Fe) and chromium (Cr). According to the disclosure, the metal plate includes a surface layer at least in one sub-region including at least aluminum oxide and titanium oxide.

In some examples, a technique including positioning supports such that the supports are between a first metallic substrate and a second metallic substrate, wherein an undulating member is located between the first metallic substrate and the second metallic substrate, the undulating member defining a plurality of first peaks adjacent to a first surface of the first metallic substrate and a plurality of second peaks adjacent to a second surface of the second metallic substrate, wherein a first support of the supports is positioned such that the first support extends between a first peak of the plurality of first peaks and the second surface of the second metallic substrate; welding the first peak to the first surface of the first metallic substrate in an area of the first support; and removing the first support by at least one of a thermal removal process or a chemical removal process.

A repair pin-stud used in processes for repairing panels, such as honeycomb panels. The repair pin-stud includes a cylindrical stud member, a tip on a first end of the cylindrical stud member, and an elongated installation member connected to a second end of the cylindrical stud member. The repair pin-stud further includes a tubular pin concentric with the cylindrical stud member. A first end of the tubular pin is connected to the cylindrical stud member, and a second end of the tubular pin is open and the elongated installation member extends outwardly from the second end of the tubular pin.

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved structure formation, part creation and manipulation, use of multiple additive manufacturing systems, and high throughput manufacturing methods suitable for automated or semi-automated factories are also disclosed.

An additive manufacturing system including a two-dimensional energy patterning system for imaging a powder bed is disclosed. Improved chamber designs, multiple chambers, powder handling and re-use systems, and powder characterization methods are disclosed.