A method of making a metal-polymer composite includes dealloying metallic powder to yield porous metal particles, monitoring a temperature of the mixture, controlling the rate of combining, a maximum temperature of the mixture, or both, and combining the porous metal particles with a polymer to yield a composite. Dealloying includes combining the metallic powder with an etchant to yield a mixture. A metal-polymer composite includes porous metal particles having an average particle size of about 0.2 ?m to about 500 ?m and a thermoplastic or thermoset polymer. The polymer composite comprises at least 10 vol % of the porous metal particles. A powder mixture includes porous metal particles having an average particle size of about 0.2 ?m to about 500 ?m and a metal powder. The powder mixture includes about 1 wt % to about 99 wt % of the porous metal particles.

A method of making a metal-polymer composite includes dealloying metallic powder to yield porous metal particles, monitoring a temperature of the mixture, controlling the rate of combining, a maximum temperature of the mixture, or both, and combining the porous metal particles with a polymer to yield a composite. Dealloying includes combining the metallic powder with an etchant to yield a mixture. A metal-polymer composite includes porous metal particles having an average particle size of about 0.2 ?m to about 500 ?m and a thermoplastic or thermoset polymer. The polymer composite comprises at least 10 vol % of the porous metal particles. A powder mixture includes porous metal particles having an average particle size of about 0.2 ?m to about 500 ?m and a metal powder. The powder mixture includes about 1 wt % to about 99 wt % of the porous metal particles.

Methods of printing an object via a 3-dimensional printer include printing a shell and an infill structure. The shell defines an exterior of an object and includes one or more apertures enabling flow of a debinder solvent therethrough. The infill structure occupies a volume encompassed by the shell, and defines a network of interconnected channels. During a debing of the object, the network enables percolation of a debinder solvent through the structure and the one or more apertures. As a result, the object is debinded efficiently and in minimal time.

Included is a method of preparing a compound for bonded magnets, the method including: coating a magnetic material having an average particle size of 10 m or less with a thermosetting resin and a curing agent at a ratio of the equivalent weight of the curing agent to the equivalent weight of the thermosetting resin of 2 or higher and 10 or lower to obtain a coated material; granulating the coated material by compression to obtain a granulated product; milling the granulated product to obtain a milled product; and surface treating the milled product with a silane coupling agent to obtain a compound for bonded magnets, the method either including, between the granulation and the milling, heat curing the granulated product to obtain a cured product, or including, between the milling and the surface treatment, heat curing the milled product to obtain a cured product.

A system for developing a composition for powder molding which, after a viscosity of the composition for powder molding and a degreasing process, extracts optimal compositional information of the composition in terms of the ratios of the residual binder materials is disclosed. Such a system includes a searching logic unit configured, after generating a plurality of candidate compositional information, to extract the optimal compositional information therefrom and a synthesis/analysis module configured to synthesize and analyze compositions corresponding to the plurality of candidate compositional information and provide to the searching logic unit measurement information on the viscosities of the compositions corresponding to each of the plurality of candidate compositional information and ratios of residual binder materials after a degreasing process. Also, the searching logic unit extracts the optimal compositional information based on the candidate compositional information and the measurement information thereof.

A cam follower roller device comprising a tappet body extending along a longitudinal axis and defining a tappet bore, and a bearing assembly mounted in the tappet bore. The bearing assembly includes a pin centered on a pin transverse axis (the transverse axis is perpendicular to the longitudinal axis), and a roller rotatably mounted on the pin. The tappet body is made by a metal injection molding process including successive steps of mixing a metal powder with a thermoplastic binder, forming a part by injection of the mixed powder in a closed die, debinding the formed part in a furnace, sintering to densify the part, and quenching to set a tappet body hardness, to improve wear resistance and fatigue life.

A cam follower roller device comprising a tappet body extending along a longitudinal axis and defining a tappet bore, and a bearing assembly mounted in the tappet bore. The bearing assembly includes a pin centered on a pin transverse axis (the transverse axis is perpendicular to the longitudinal axis), and a roller rotatably mounted on the pin. The tappet body is made by a metal injection molding process including successive steps of mixing a metal powder with a thermoplastic binder, forming a part by injection of the mixed powder in a closed die, debinding the formed part in a furnace, sintering to densify the part, and quenching to set a tappet body hardness, to improve wear resistance and fatigue life.

The present invention discloses a slurry feedstock for extrusion-based three-dimensional, 3D, printing of a functionally graded article, and/or for casting an article under a low pressure at a room temperature, a method of preparing the same, a method of extrusion-based 3D printing and/or casting, and a system therefor. The slurry feedstock comprises a build material comprising a metal, a ceramic or any combinations thereof, an organic polymer binder, an additive and a volatile organic solvent. The build material mixed with the additive and the organic polymer binder dissolved with the volatile organic solvent form a first pre-mix and a second pre-mix, respectively, that are mixed to form a substantially homogeneous and flowable slurry mixture that is used for producing articles.

The present invention discloses a slurry feedstock for extrusion-based three-dimensional, 3D, printing of a functionally graded article, and/or for casting an article under a low pressure at a room temperature, a method of preparing the same, a method of extrusion-based 3D printing and/or casting, and a system therefor. The slurry feedstock comprises a build material comprising a metal, a ceramic or any combinations thereof, an organic polymer binder, an additive and a volatile organic solvent. The build material mixed with the additive and the organic polymer binder dissolved with the volatile organic solvent form a first pre-mix and a second pre-mix, respectively, that are mixed to form a substantially homogeneous and flowable slurry mixture that is used for producing articles.

A printer fabricates an object from a computerized model using a fused filament fabrication process. The shape of an extrusion nozzle may be varied during extrusion to control, e.g., an amount of build material deposited, a shape of extrudate exiting the nozzle, a feature resolution, and the like.