A small scale, high speed turbomachine is described, as well as a process for manufacturing the turbomachine. The turbomachine is manufactured by diffusion bonding stacked sheets of metal foil, each of which has been pre-formed to correspond to a cross section of the turbomachine structure. The turbomachines include rotating elements as well as static structures. Using this process, turbomachines may be manufactured with rotating elements that have outer diameters of less than four inches in size, and/or blading heights of less than 0.1 inches. The rotating elements of the turbomachines are capable of rotating at speeds in excess of 150 feet per second. In addition, cooling features may be added internally to blading to facilitate cooling in high temperature operations.

An impact attenuation system comprises an aluminum honeycomb sheet having a top surface and a bottom surface. The aluminum honeycomb sheet defines a plurality of approximately hexagonally shaped cells. The bottom surface defines a single sheet of contiguous cells and the top surface defines two or more islands of contiguous cells separated by one or more slits. At least a portion of one or both of the top surface and bottom surface may be covered by a polymer skin. The polymer skin may comprise carbon fibers and/or fiberglass.

A method of additive manufacturing of a component includes cutting a plurality of sheets, each sheet corresponding to a respective cross-section of the component, tack welding the sheets to one another to form a stack, arranging the stack in a mold, and spark plasma sintering the tack-welded stack of sheets to reduce vacancies and dislocations between adjacent sheets of the stack.

A method for additive manufacturing of a three-dimensional object includes: a) identifying a set of sequentially extending planar cross-sectional shapes of the three-dimensional object; b) cutting a metal sheet into a plurality of planar metal pieces, each metal piece cut to a metal piece shape corresponding to a respective one of the cross-sectional shapes, wherein the metal sheet has a first face with a first plurality of barbs extending therefrom, and an opposed second face with a second plurality of barbs extending therefrom; c) cutting a substrate sheet into a plurality of planar substrate pieces, each substrate sheet cut to a substrate piece shape corresponding to a respective one of the cross-sectional shapes; and d) positioning the metal pieces and the substrate pieces in facing relation in an alternating pattern and in sequential order, and pressing the metal pieces and substrate pieces together to force the barbs to penetrate the substrate pieces.

A method of manufacturing a part using a cutting machine includes placing a non-porous sheet on a surface of a material cutting machine, removing material from the non-porous sheet to form a plurality of sections of the part, and while the non-porous sheet is present on the material cutting machine, forming fastening holes within the sections. The method further includes removing the sections from a remainder of the sheet, placing the sections together such that each section of the part abuts another section, and inserting fasteners through the fastening holes of the sections.

A method and a system are disclosed for making an article of manufacture from a blank defining an internal opening. A stack of blanks are aligned and the internal openings of the blanks in the stack of blanks are machined by a rotary cutting tool to a finished dimension. The blanks are clamped together before machining in a numerically controlled machine tool. The blanks are subsequently formed individually in a sheet metal forming operation in which the inner perimeter of the internal openings is expanded as the blank is formed.

A method for making a screw hole in a workpiece including a plate-shaped portion includes: preparing an auxiliary member having a flat plate shape; forming, in the plate-shaped portion, a first pilot hole having a minor diameter smaller than a major diameter of the screw hole; forming, in the auxiliary member, a second pilot hole having a minor diameter smaller than the major diameter of the screw hole; fixing the auxiliary member to the plate-shaped portion so that the first pilot hole is concentric with the second pilot hole; and making the screw hole in the plate-shaped portion and the auxiliary member by inserting a tap in the first pilot hole and the second pilot hole.

The present invention discloses a vacuum glass middle support placing system that includes a glass plate placing station, a middle support placing station, a vacuum sealing station, a pallet and a conveyor. The pallet is directly conveyed by the conveyor to transfer it among the stations and the glass plate is placed on the pallet at the glass plate placing station. The pallet includes a supporting face that is matched with a surface of the glass plate and a glass plate positioning structure. A magnetic attraction surface array made of permanent magnets and corresponding to the middle supports to be placed on the glass plate is arranged on the supporting face.

A clinch pin fastener comprises a lamination of layers bonded face-to-face. The individual layers can be formed by stamping or photo etching and can be bonded together by soldering, by using an adhesive or by ultrasonic bonding. The heads of the outermost layers may include a tab at the top which extends laterally at a 90-degree angle to the outermost layer. The fasteners are preferably constructed by bonding elongate strips to form a continuous string of fasteners joined side-to-side at integral, severable joints located between adjacent heads of the fasteners. The fasteners can be wound about a supply reel without a carrier and thereafter unwound from the reel as they are installed.

A method and system for fabricating a part includes sectionalizing a computer-generated representation of a part into strata having an order, forming layers corresponding to the strata from sheet material, stacking at least two of the layers in the order, and joining the layers together. The method and system are suitable for producing a phase-change material container for a thermal energy harvesting device, for example.