A method for additively manufacturing a component includes generating, via imaging software, a plurality of slices of a support structure of the component based on component geometry. The method also includes melting or fusing, via the additive manufacturing system, layers of material to a build platform of the component so as to form the support structure according to the plurality of slices. The support structure includes a lattice configuration having of a plurality of support members arranged together to form a plurality of cells. Further, the method includes melting or fusing, via the additive manufacturing system, a component body to the support structure. After the component body solidifies, the method includes removing all of the support structure from the component body to form the component.

A method for manufacturing a rare earth permanent magnet includes manufacturing an NdFeB sintered magnet. A grain boundary diffusion material in the form of a mixed powder comprising an alloy powder containing Re.sup.1.sub.aM.sub.b or M; and Re.sup.2 hydride or Re.sup.2 fluoride is disposed on a surface of the NdFeB sintered magnet. The grain boundary diffusion material is heated to diffuse at least one of Re.sup.1, Re.sup.2 and M into a grain boundary part inside the sintered magnet or a grain boundary part region of a sintered magnet main phase grain. Re.sup.1 and Re.sup.2 are each rare earth elements selected from the group consisting of dysprosium, terbium, neodymium, praseodymium, and holmium, M is a metal compound consisting of copper, zinc, tin, and aluminum, 0.1<a<99.9, and a+b=100.

A method for manufacturing a rare earth permanent magnet includes manufacturing an NdFeB sintered magnet. A grain boundary diffusion material in the form of a mixed powder comprising an alloy powder containing Re.sup.1.sub.aM.sub.b or M; and Re.sup.2 hydride or Re.sup.2 fluoride is disposed on a surface of the NdFeB sintered magnet. The grain boundary diffusion material is heated to diffuse at least one of Re.sup.1, Re.sup.2 and M into a grain boundary part inside the sintered magnet or a grain boundary part region of a sintered magnet main phase grain. Re.sup.1 and Re.sup.2 are each rare earth elements selected from the group consisting of dysprosium, terbium, neodymium, praseodymium, and holmium, M is a metal compound consisting of copper, zinc, tin, and aluminum, 0.1<a<99.9, and a+b=100.

A monolithic structure containing several physical structures with features in the size range of 0.1-5000 micrometers. At least one of the physical structures contains of 3-dimensional surfaces, at least one of which is curved. Further, at least two of the 3-dimensional surfaces have varying orientations with respect to an external surface of the monolithic structure. A method of making a monolithic structure. The method includes generating computer aided design (CAD) files suitable for additive manufacturing of physical structures required for a monolithic structure. Utilizing the generated CAD files and specified materials, the physical structures containing features in the size range of 0.1-5000 micrometers are fabricated by additive manufacturing, At least one of the physical structure has 3-dimensioal surfaces wherein at least one of the 3-dimensional surface is curved and at least two of which have varying orientations with respect to an external surface of the monolithic structure.

A monolithic structure containing several physical structures with features in the size range of 0.1-5000 micrometers. At least one of the physical structures contains of 3-dimensional surfaces, at least one of which is curved. Further, at least two of the 3-dimensional surfaces have varying orientations with respect to an external surface of the monolithic structure. A method of making a monolithic structure. The method includes generating computer aided design (CAD) files suitable for additive manufacturing of physical structures required for a monolithic structure. Utilizing the generated CAD files and specified materials, the physical structures containing features in the size range of 0.1-5000 micrometers are fabricated by additive manufacturing, At least one of the physical structure has 3-dimensioal surfaces wherein at least one of the 3-dimensional surface is curved and at least two of which have varying orientations with respect to an external surface of the monolithic structure.

A method for manufacturing a decorative article (2) including the following steps of: making a blank by injection moulding a material comprising a metallic material, machining and/or polishing the blank to form a product, and forming the product to print a raised or recessed relief pattern (3) on part of the surface of the product, the product with the pattern (3) forming the decorative article. Also, a decorative article, notably an external timepiece part made of a sintered material having on part of its surface a raised or recessed relief pattern (3) made by a forming process. Preferably, the sintered material is a grade 5 titanium alloy (Ti6V4Al) or a stainless steel.

A fabrication method involving the use of additive material fabrication methods to create a shell representative of a desired part, the additive material shell being used in one or more molding fabrication methods in which a second material is provided into a cavity of the shell.

A fabrication method involving the use of additive material fabrication methods to create a shell representative of a desired part, the additive material shell being used in one or more molding fabrication methods in which a second material is provided into a cavity of the shell.

A method for manufacturing a porous metal with enhanced ability to bond to a plastic subsequently powder feed for injection molding process provides a powder feed to an injection molding process, to form a green embryo. The green embryo is sent into a sintering furnace for high-temperature sintering to obtain a blank sintered product. A chemical reagent is applied to form pores on the sintered product. The powder feed includes first and second metal powders evenly mixed. The second metal powder has a mass percentage of about less than 10% of a total mass of the powder feed for injection molding process. The first metal powder is corrosion-resistant. The second metal powder is readily corrodible.

A method for the manufacture of a three-dimensional object using a refractory matrix material is provided. The method includes the additive manufacture of a green body from a powder-based refractory matrix material followed by densification via chemical vapor infiltration (CVI). The refractory matrix material can be a refractory ceramic (e.g., silicon carbide, zirconium carbide, or graphite) or a refractory metal (e.g., molybdenum or tungsten). In one embodiment, the matrix material is deposited according to a binder-jet printing process to produce a green body having a complex geometry. The CVI process increases its density, provides a hermetic seal, and yields an object with mechanical integrity. The residual binder content dissociates and is removed from the green body prior to the start of the CVI process as temperatures increase in the CVI reactor. The CVI process selective deposits a fully dense coating on all internal and external surfaces of the finished object.