An object printed by a three-dimensional (3D) printer includes a plurality of layers of material printed by the 3D printer. The layers of material bond together to form the object as the layers of material cool and solidify after being printed by the 3D printer. The object also includes a temperature sensor placed in contact with one or more of the layers when the layers of material are being printed by the 3D printer. The temperature sensor remains in contact with the object after the layers of material cool and solidify to form the object. The temperature sensor is configured to measure a temperature of the object after the layers of material cool and solidify to form the object.

Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

This application relates to a method of preparing a composite material for an electric wiring connector. In one embodiment, the method includes preparing a powder mixture including (i) a metal powder composed of aluminum or aluminum alloy particles and magnesium particles and (ii) a polymer powder. The method may also include sintering the powder mixture to produce a composite material for the electric wiring connector using a spark plasma sintering (SPS) process. This application also relates to a composite material for an electric wiring connector prepared through the method described above. This application further relates to a method of manufacturing an electric wiring connector, the method including forming a housing of the electric wiring connector with the composite material. This application further relates to an electric wiring connector manufactured by the method.

This application relates to a method of preparing a composite material for an electric wiring connector. In one embodiment, the method includes preparing a powder mixture including (i) a metal powder composed of aluminum or aluminum alloy particles and magnesium particles and (ii) a polymer powder. The method may also include sintering the powder mixture to produce a composite material for the electric wiring connector using a spark plasma sintering (SPS) process. This application also relates to a composite material for an electric wiring connector prepared through the method described above. This application further relates to a method of manufacturing an electric wiring connector, the method including forming a housing of the electric wiring connector with the composite material. This application further relates to an electric wiring connector manufactured by the method.

This invention teaches a quality assurance system for additive manufacturing. This invention teaches a multi-sensor, real-time quality system including sensors, affiliated hardware, and data processing algorithms that are Lagrangian-Eulerian with respect to the reference frames of its associated input measurements. The quality system for Additive Manufacturing is capable of measuring true in-process state variables associated with an additive manufacturing process, i.e. those in-process variables that define a feasible process space within which the process is deemed nominal. The in-process state variables can also be correlated to the part structure or microstructure and can then be useful in identifying particular locations within the part likely to include defects.

A manifold structure is formed using ultrasonic additive manufacturing and machining. The manifold structure includes a body having a base plate and a cover plate that define a flow passage therebetween, and a plurality of walls that segment the flow passage into a plurality of channels, wherein each of the walls has a height extending from the base plate to the cover plate and a non-linear length that is elongated relative to a width of the wall and extends in a direction normal to the height of the wall. The walls are wavy in shape to provide enhanced rigidity and stiffness during lamination over the channels.

A manifold structure is formed using ultrasonic additive manufacturing and machining. The manifold structure includes a body having a base plate and a cover plate that define a flow passage therebetween, and a plurality of walls that segment the flow passage into a plurality of channels, wherein each of the walls has a height extending from the base plate to the cover plate and a non-linear length that is elongated relative to a width of the wall and extends in a direction normal to the height of the wall. The walls are wavy in shape to provide enhanced rigidity and stiffness during lamination over the channels.

A component for a mirror array for EUV lithography, particularly for use in faceted mirrors in illumination systems of EUV lithography devices. A component (500) for a mirror array for EUV lithography is proposed which is at least partially made from a composite material including matrix material (502) that contains copper and/or aluminium, and reinforcing material in the form of fibers (504). The composite material also includes particles (508) that consist of one or more of the materials from the group: graphite, adamantine carbon, and ceramic.

A component for a mirror array for EUV lithography, particularly for use in faceted mirrors in illumination systems of EUV lithography devices. A component (500) for a mirror array for EUV lithography is proposed which is at least partially made from a composite material including matrix material (502) that contains copper and/or aluminium, and reinforcing material in the form of fibers (504). The composite material also includes particles (508) that consist of one or more of the materials from the group: graphite, adamantine carbon, and ceramic.