A precast composite wall structure and method for forming the wall structure are disclosed. The method includes providing a casting bed defining a plurality of shapes corresponding to a three-dimensional outer surface of a wall structure, placing a first layer of uncured concrete to conform to the shapes defined by the lower surface, positioning a forming member in overlying relation above the frame, the forming member defining a plurality of rectangular-shaped channels therebetween, positioning a stud frame within the casting bed along the forming member, placing a second layer of uncured concrete within the casting bed to conform to the rectangular-shaped channels between the rectangular protrusions, and allowing the concrete to cure.

A method of manufacturing a component (100) having a main part (101) and a projecting feature (104,114), the method comprising providing a shaped void (210) corresponding to the component, locating a pre-formed element (214) in a feature region of the shaped void which corresponds to the projecting feature, locating powder (212) within the shaped void; and forming the element and the powder into the component such that the element creates at least a part of the projecting feature.

A composite component for a gas turbine engine is provided, along with its methods of formation. The composite component includes: an additively printed inner portion defining at least one flowpath feature, and a ceramic matrix composite (CMC) outer portion formed on the additively printed inner portion such that the CMC outer portion substantially surrounds the additively printed inner portion. The additively printed inner portion includes SiC; and the CMC outer portion includes a fiber reinforced ceramic matrix (e.g., including SiC) and defines at least one cooling cavity fluidly coupled to the at least one flowpath feature of the additively printed inner portion.

A method of forming a coating includes providing a mold that has a flexible wall that defines a mold cavity, inserting a component that is to be coated into the mold cavity, the component having a component surface roughness and there being a coating gap defined between the component and the flexible wall of the mold cavity, introducing a molding slurry into the mold cavity, the molding slurry filling the coating gap and contacting the component so as to overcoat the component surface roughness, solidifying the molding slurry to form a green coating on the component, and consolidating the green coating to form a final coating on the component, the final coating having a coating surface roughness that is less than the component surface roughness.

A coating system includes a mold having a flexible wall defining a mold cavity, a component disposed in the mold cavity, there being a coating gap defined between the component and the flexible wall of the mold cavity, and either a molding slurry or a solidified molding slurry filling the coating gap.

Improved tilt-up and precast construction panels and improved methods for creating the same address deficiencies in the current tilt-up and precast construction panels. Improved tilt-up and precast construction panels use less concrete and less steel reinforcement and weigh less than current tilt-up and precast construction panels. Additionally, improved tilt-up and precast construction panels have greater insulative properties (both heat and sound) than do current tilt-up and precast construction panels. Improved tilt-up and precast construction panels require less labor on the construction site, thereby increasing efficiency and profitability of construction crews. Additional advantages of implementations of the invention will become apparent through the following description and by practice of implementations of the invention.