A method of fabricating a fuel injector nozzle comprising the steps of: (a) forming a first microstructured pattern in a first material; (b) replicating the first microstructured pattern in a second material to make a first mold comprising a second microstructured pattern in the second material; (c) replicating the second microstructured pattern in a third material to make a second mold comprising a third microstructured pattern comprising a plurality of microstructures in the third material; (d) replicating the third microstructured pattern in a metal material to make a replicated structure; and (e) removing the third material resulting in a nozzle having a plurality of through-holes through the metal material and corresponding to the plurality of microstructures in the third microstructured pattern. Each of the plurality of through-holes has a hole wall connecting a hole entry to a hole exit, and the hole wall of at least one through-hole has a side that curves from its hole entry to its hole exit.

Methods of making nozzles are disclosed. More specifically, methods of making nozzles that may be used as components of a fuel injection system are disclosed.

Methods of making nozzles are disclosed. More specifically, methods of making nozzles that may be used as components of a fuel injection system are disclosed.

A fuel injector nozzle comprising a plurality of holes formed therethrough connecting one side of the nozzle with an opposite side of the nozzle. Each of the holes comprises a hole entry on the one side of the nozzle having a first shape, a hole exit on the opposite side of the nozzle having a second shape, and a hole wall connecting the hole entry to the hole exit. The hole exit is smaller than the hole entry, and the hole wall comprises a side that is continuously curved from the hole entry to the hole exit.

A fuel injector nozzle comprising a plurality of holes formed therethrough connecting one side of the nozzle with an opposite side of the nozzle. Each of the holes comprises a hole entry on the one side of the nozzle having a first shape, a hole exit on the opposite side of the nozzle having a second shape, and a hole wall connecting the hole entry to the hole exit. The hole exit is smaller than the hole entry, and the hole wall comprises a side that is continuously curved from the hole entry to the hole exit.

Methods and systems for preparing a hole having an accurately controlled area in an orifice plate for a mass flow controller are provided. Methods involve forming an initial hole in the orifice plate. The initial hole has an opening having an initial area. The orifice plate comprises a material that can react to form a coating on the orifice plate. The coating occupies a greater volume than the material consumed to form the coating. The material of the orifice plate is reacted with a reactant to produce the coating and thereby produce a reduced area hole having an opening with a reduced area that is smaller than the initial area. The reduced area hole is measured. A determined amount of the coating is removed from at least the reduced area hole to produce a final hole in the orifice plate, wherein the reduced area is smaller than an opening area of the final hole.

Methods and systems for preparing a hole having an accurately controlled area in an orifice plate for a mass flow controller are provided. Methods involve forming an initial hole in the orifice plate. The initial hole has an opening having an initial area. The orifice plate comprises a material that can react to form a coating on the orifice plate. The coating occupies a greater volume than the material consumed to form the coating. The material of the orifice plate is reacted with a reactant to produce the coating and thereby produce a reduced area hole having an opening with a reduced area that is smaller than the initial area. The reduced area hole is measured. A determined amount of the coating is removed from at least the reduced area hole to produce a final hole in the orifice plate, wherein the reduced area is smaller than an opening area of the final hole.

A method of fabricating a nozzle that includes casting and curing a first material using a patterned nip roller to form a first microstructured pattern of discrete microstructures, deforming at least one of the discrete microstructures; replicating the first microstructured pattern, including the at least one deformed discrete microstructure, in a second material different than the first material to make a replicated structure comprising a plurality of blind holes formed in the second material, removing second material of the replicated structure to expose tops of microstructures in the first microstructured pattern, and removing the first material from the replicated structure, resulting in a nozzle having a plurality of through-holes in the second material and corresponding to the first microstructured pattern.

A method of fabricating a nozzle that includes casting and curing a first material using a patterned nip roller to form a first microstructured pattern of discrete microstructures, deforming at least one of the discrete microstructures; replicating the first microstructured pattern, including the at least one deformed discrete microstructure, in a second material different than the first material to make a replicated structure comprising a plurality of blind holes formed in the second material, removing second material of the replicated structure to expose tops of microstructures in the first microstructured pattern, and removing the first material from the replicated structure, resulting in a nozzle having a plurality of through-holes in the second material and corresponding to the first microstructured pattern.

A method of manufacturing a last chance screen for an aircraft engine includes forming an array of holes through a metal sheet with a wire electrode using electrical discharge machining. The array of holes comprises a plurality of holes. Each hole of the plurality of holes comprises a first end and a second end and is surrounded by a wall section such that the last chance screen is defined by the plurality of holes and the plurality of wall sections. The first and second end of each hole are widened by either applying a flow of an abrasive flow medium to the array of holes in two directions or using a conical sinker electrode on either side of the metal sheet. Shaping the first and second end of each hole results in an airfoil-shaped cross-section of each wall section.