A method loading powder into a mold can include immersing the mold comprising one or more microchannels into a suspension comprising the powder and a surfactant suspended in a dispersant, wherein the powder comprises particles having an average particle size of less than 100 m, wherein the mold is substantially entirely covered by the suspension; heating the suspension having the mold immersed therein under a temperature condition suitable to lower the stability of the particles of the powder in the suspension such that the particles settle out of solution and into the one or more microchannels; and applying an ultrasonic wave to the heated suspension to further settle the particles of the powder into the one or more microchannels thereby filling the one or more microchannels of the mold with the powder.

The subject matter disclosed herein relates to methods of manufacturing metallic welding wires and the metallic welding wires formed thereby. A method of manufacturing a metallic welding wire includes filling a mold with a metallic powder, the metallic powder filling one or more narrow elongated tubes within the mold, and heat treating the tubes filled with the metallic powder, thereby forming a solid metallic welding wire within each tube.

Methods for fabricating an interconnect for a fuel cell system that include forming a metal powder into a preform structure, positioning the preform structure in a die cavity of a press apparatus, and compressing the preform structure in the press apparatus to form the interconnect. Further embodiments include use of thin inserts in the die cavity to provide reduced permeability and/or including filler material in the die cavity.

Methods for fabricating an interconnect for a fuel cell system that include forming a metal powder into a preform structure, positioning the preform structure in a die cavity of a press apparatus, and compressing the preform structure in the press apparatus to form the interconnect. Further embodiments include use of thin inserts in the die cavity to provide reduced permeability and/or including filler material in the die cavity.

Additive manufacturing (AM) exploits materials added layer by layer to form consecutive cross sections of desired shape. However, prior art AM suffers drawbacks in employable materials and final piece-part quality. Embodiments of the invention introduce two new classes of methods, solidification and trapping, to create complex and functional structures of macro/micro and nano sizes using configurable fields irrespective of whether they need a medium or not for transmission. Selective Spatial Solidification forms the piece-part directly within the selected build material whilst Selective Spatial Trapping injects the build material into the chamber and selectively directs it to accretion points in a continuous manner. In each a localized spatiotemporal concentrated field is established by configuring or maneuvering field emitters. These methods are suitable to create any 3D part with high mechanical properties and complex geometries. These layerless methods may be used discretely or in combination with conventional AM and non-AM manufacturing processes.

A method of additively manufacturing an object includes successively forming a plurality of powder layers by depositing powder over a build platform using a powder-deposition apparatus. The method also includes successively forming a binder shell by bonding select regions of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers using a binder-delivery apparatus. The binder shell encloses a portion of the powder. The method further includes densifying the portion of the powder bound by the binder shell using a consolidation apparatus.

A method of additively manufacturing an object includes successively forming a plurality of powder layers by depositing powder over a build platform using a powder-deposition apparatus. The method also includes successively forming a binder shell by bonding select regions of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers using a binder-delivery apparatus. The binder shell encloses a portion of the powder. The method further includes densifying the portion of the powder bound by the binder shell using a consolidation apparatus.

A method of manufacturing a multi-material tubular structure includes spinning a can, depositing a powdered material into the can and compacting the powdered material within the can to provide a tubular structure.

A method of manufacturing a multi-material tubular structure includes spinning a can, depositing a powdered material into the can and compacting the powdered material within the can to provide a tubular structure.

A method of manufacturing a multi-material tubular structure includes spinning a can, depositing a powdered material into the can and compacting the powdered material within the can to provide a tubular structure.