A conductor assembly can include one or more conductors formed by a conductive material, and one or more filter cores formed integrally on and at least partially around the one or more conductors. The one or more filter cores can be formed of a material different than the conductive material and can be configured to reduce electromagnetic emissions from the one or more conductors.

A method for fabricating heat exchangers using additive manufacturing technologies. Additive manufacturing enables the manufacture of heat exchangers with complex geometries and/or with internal and external integral surface features. Additive manufacture also facilitates the manufacture of heat exchangers with regional variations, such as changes in size, shape and surface features. In one embodiment, the present invention provides a heat exchanger with a helicoidal shape that provides axial elastic compliance. In one embodiment, the internal channel of the heat exchanger varies along its length. The internal channel may have a cross-sectional area that increases progressively from one end to the other. In one embodiment, the external shape of the tubular structure may be non-circular to optimize heat transfer with an external heat transfer fluid. In one embodiment, the present invention provides a heat pipe with an internal wicking structure formed as an integral part of the additive manufacturing process.

Various embodiments discussed in the present document relate to an implant assembly. The implant assembly includes a porous metal coating. The implant assembly further includes a biocompatible implant material. A polymeric binder layer is disposed between the porous metal coating and the biocompatible implant material.

Vehicle structural components and additive manufacturing methods for forming the components are described. The structural components incorporate hydrogen storage materials for use in conjunction with hydrogen fuel cells in electric-powered vehicles such as unmanned aerial vehicles. The hydrogen storage materials can be in the form of a 3D printed metal foam that includes a metal hydride and an inert structural metal. The material can exhibit a very low weight density able to store hydrogen in a low pressure solid-state form at a high energy density. The structural components that carry the hydrogen storage materials can be exchangeable components of a vehicle, and the vehicle can be refueled by merely exchanging an exhausted component for a replacement component that is fully-charged with hydrogen.

A heat sink includes a baseplate of thermally-conductive material and a radiator for transferring heat to atmosphere around the radiator. The baseplate is configured to be in thermal communication with a heat source, such as an integrated circuit or a power electronic device. The radiator is disposed upon the baseplate and includes a skin of melted material formed by additive manufacturing which encloses a chamber. An outer wick of porous material is disposed within the chamber, the outer wick coats an inner surface of the skin. A refrigerant is disposed within the chamber. The refrigerant changes between a liquid phase and a vapor phase to convey heat from the baseplate to the skin, and is conveyed back through the wick in the liquid phase by capillary action. The radiator also includes a plurality of fins extending from a cover to promote heat transfer to the atmosphere.

A mold includes a pair of first mold parts, a pair of second mold parts, and a pair of third mold parts that define six surfaces of a molding space substantially having a rectangular parallelepiped shape. At least one of the pair of third mold parts includes an upper mold part and a lower mold part. The upper mold part defines an upper space of the molding space, and the lower mold part defines a lower space of the molding space. The upper mold part and the lower mold part are individually slidable. The lower mold part is configured to protrude toward the molding space with respect to the upper mold part so that a step portion is formed. The upper mold part is configured to be slidable relative to the lower mold part to make a size of the step portion decrease. The upper mold part and the lower mold part are configured to be integrally slidable in a state that the step portion remains or is absent.

The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.

The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.

The present application provides a method for preparing a metal foam. The present application provides a method which can freely control characteristics, such as pore size and porosity, of the metal foam, prepare the metal foam in the form of films or sheets which have conventionally been difficult to produce, particularly the form of thin films or sheets as well, and prepare a metal foam having excellent other physical properties such as mechanical strength. According to one example of the present application, it is possible to efficiently form a structure in which such a metal foam is integrated on a metal base material with good adhesive force.

A vapor chamber includes a wick structure created by an additive selective laser sintering process. The wick structure includes a substrate, a first copper powder layer, a second copper powder layer, and a plurality of additional layers. The first copper powder layer is deposited across the substrate, wherein the first copper powder layer is subsequently selectively fused via a fusing instrument. The second copper powder layer is deposited across the first copper powder layer, wherein the second copper powder layer is subsequently selectively fused via the fusing instrument. Additionally, a plurality of additional copper powder layers are deposited wherein each additional layer is deposited on the previous layer, wherein each of the additional copper powder layers is selectively fused with a predetermined structure.