A three-dimensional shaped article production method is a three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers and includes a first metal powder supply step of supplying a first metal powder having a first average particle diameter to a shaping table, a layer formation step of forming the layer by compressing the first metal powder supplied to the shaping table, a first liquid supply step of supplying a first liquid containing a second metal powder having a second average particle diameter and a binder to a portion of a constituent region of the three-dimensional shaped article, a second liquid supply step of supplying a second liquid containing at least either the second meal powder at a lower concentration than the first liquid or a third metal powder having a larger average particle diameter than the second average particle diameter and containing a binder to at least a portion of a surface layer region, and a sintering step of sintering a metal in the constituent region by heating a stacked body.

A tooling assembly and method of aligning a plurality of components for a repair process in an additive manufacturing machine includes positioning the plurality of components such that a repair surface of each of the plurality of components contacts an alignment plate, e.g., under the force of gravity or using biasing members. The method further includes surrounding the alignment plate with containment walls to define a reservoir around the plurality of components and dispensing a fill material, such as wax or a potting material, into the reservoir which is configured for fixing a relative position of the plurality of components when the fill material is solidified.

A tooling assembly for mounting a plurality of components, such as compressor blades, in a powder bed additive manufacturing machine to facilitate a repair process is provided. The tooling assembly includes component fixtures configured for receiving each of the compressor blades, a mounting plate for receiving the component fixtures, and a complementary fixture defining a plurality of voids within which the compressor blades are received when the complementary fixture is mounted to the mounting plate such that less powder is required to fill the powder bed.

An additive manufacturing machine for repairing a component includes a build platform that supports the component and a powder dispensing assembly for selectively depositing additive powder over the build platform. A powder seal assembly includes a powder support plate positioned above the build platform and defining an aperture for receiving the component without contacting the component. A clamping mechanism is movable relative to the powder support plate and defines a void for receiving a resilient sealing element around the aperture. An actuating mechanism, such as bolts or a linear actuator, moves the clamping mechanism toward the powder support plate to deform the resilient sealing element until the resilient sealing element contacts and forms a seal with the component.

An additive manufacturing machine for repairing a component includes a build platform that supports the component and a powder dispensing assembly for selectively depositing additive powder over the build platform. A powder seal assembly includes a powder support plate positioned above the build platform and defining an aperture for receiving the component without contacting the component. An inflatable sealing element is operably coupled to the powder support plate around the aperture and is inflated to contact and seal against the component, thereby forming a support surface above the build platform upon which additive powder may be deposited.

A piece of flexible porous metal foil is a sheet made of porous metal material using solid solution alloy, face-centered cubic metal simple substance or body-centered cubic metal simple substance as matrix phase. The thickness of the sheet is 5 to 200 micrometers, the average aperture thereof is 0.05 to 100 micrometers, the porosity thereof is 15-70%, and the sheet is made by sintering a homogeneous film. The preparation method for the flexible porous metal foil comprises: (1) preparing thick turbid liquid with raw material powder forming the metal porous material by using dispersing agent and binding agent; (2) injecting the turbid liquid into a mold cavity of a film manufacturing fixture, and drying the turbid liquid to form a piece of homogeneous film; (3) putting the film into a sintering manufacturing fixture matching with the film in shape, then sintering the film, and taking the film out after sintering and obtaining the flexible porous metal foil. The flexible porous metal foil made by the above method can be used in many fields, and have ideal performance in flexible and chemical stability.

A curable resin or adhesive composition includes at least one monomer, a photoinitiator capable of initiating polymerization of the monomer when exposed to light, and at least one energy converting material, preferably a phosphor, capable of producing light when exposed to radiation (typically X-rays). The material is particularly suitable for bonding components at ambient temperature in situations where the bond joint is not accessible to an external light source. An associated method includes: placing a polymerizable adhesive composition, including a photoinitiator and energy converting material, such as a down-converting phosphor, in contact with at least two components to be bonded to form an assembly; and, irradiating the assembly with radiation at a first wavelength, capable of conversion (down-conversion by the phosphor) to a second wavelength capable of activating the photoinitiator, to prepare items such as inkjet cartridges, wafer-to-wafer assemblies, semiconductors, integrated circuits, and the like.

A system for supporting an object created by additive manufacturing comprising the object, and a frame comprising at least one strut having a length and forming a shape at least partially surrounding the object, a runner having first and second ends, the first end integrally connected to a strut and the second end removably attached to the object.

A system for supporting an object created by additive manufacturing comprising the object, and a frame comprising at least one strut having a length and forming a shape at least partially surrounding the object, a runner having first and second ends, the first end integrally connected to a strut and the second end removably attached to the object.

A setter assembly for use in additive manufacturing a binder-jet part includes a base, a first setter component having a first setter portion and a second setter portion that may be removably coupled to the first setter portion and a plurality of protrusions disposed on and extending away from a surface of the base. The plurality of protrusions may align the base with the first setter component and enable coupling of the first setter component to the base. The setter assembly also includes a second setter component positioned between the base and the first setter component. The second setter component is disposed on the surface and the first setter component, the second setter component, and the base can be assembled onto a printed part such that at least a portion of the printed part is nested between the first setter component and the second setter component.