A method for producing a thin-walled metal part with complex geometry includes mixing a metal powder with a polymer binder in order to obtain a composite mixture, producing a flexible composite sheet from the composite mixture, cutting, in the flexible composite sheet, a preform based on a contour of the metal part, applying the preform in a mold having a surface configured with a relief of the metal part, and debinding and sintering the preform in order to obtain the metal part.

A method for producing a thin-walled metal part with complex geometry includes mixing a metal powder with a polymer binder in order to obtain a composite mixture, producing a flexible composite sheet from the composite mixture, cutting, in the flexible composite sheet, a preform based on a contour of the metal part, applying the preform in a mold having a surface configured with a relief of the metal part, and debinding and sintering the preform in order to obtain the metal part.

One aspect is an apparatus including a plurality of additively manufactured components each having an adhesive injection channel. The components are connected together such that adhesive injection channels are aligned to form an adhesive path that allows adhesive flow between the components. Another aspect is an apparatus, including an additively manufactured component having an adhesive injection channel and an adhesive flow mechanism comprising at least one of an adhesive side end effector or a vacuum side end effector, the adhesive flow mechanism configured to provide adhesive to the adhesive injection channels.

Additive manufacturing techniques are used to achieve customized preforms for repair or manufacture of turbomachinery. A method of modifying a section of a product includes forming, a preform set to fit the section. A base material is selected with properties desired for the modification of the section. A binder is selected that vaporizes at a temperature below a melting point of the base material. The preform set is built by the selective application of the binder to the base material to achieve design dimensions of the section when the preform is joined to the section. The section is prepared for effecting the extent of modification and the preform is positioned on the section. The section and the preform are heated to substantially eliminate the binder from the preform and then thermally processed to harden the preform and to bond the preform to the section.

An article comprises a first portion comprising a first alloy and a second portion comprising a second alloy that is metallurgically bonded to the first portion to form a monolithic article. The metallurgical bonding involves the application of an electrical current across the bond line and results in a retention of a metallurgical structure of the first portion and of a metallurgical structure of the second portion immediately adjacent to a bond line. The first portion has a first dominant property and the second portion has a second dominant property. The first dominant property is different from the second dominant property. The first dominant property is selected to handle operating conditions at a first position of the article where the first portion is located and the second dominant property is selected to handle operating conditions at a second position of the article where the second portion is located.

A 3D printing system comprising, an extendable body, a material delivery system, a first wall adhesion device, and a second wall adhesion device.

A 3D printing system comprising, an extendable body, a material delivery system, a first wall adhesion device, and a second wall adhesion device.

The present invention provides a bladed rotor wheel for a gas turbine engine comprising at least a rotatable forged disc, the rotatable forged disc comprising a front surface and a back surface, at least one rim surface, and a plurality of projections located on at least a portion of at least one of the front or back surface and/or on the rim surface; wherein the projections are 3D printed features protruding outwards from the front, back and/or rim surface; the projections are arranged forming a pattern so that a heat transfer capability is created at the front, back and/or rim surface; and the ratio of the distance between projections to the forged disc external radius is lower than 0.15. Furthermore, the present invention also provides a method for manufacturing a rotatable forged disc for a bladed rotor wheel.

The present invention provides a bladed rotor wheel for a gas turbine engine comprising at least a rotatable forged disc, the rotatable forged disc comprising a front surface and a back surface, at least one rim surface, and a plurality of projections located on at least a portion of at least one of the front or back surface and/or on the rim surface; wherein the projections are 3D printed features protruding outwards from the front, back and/or rim surface; the projections are arranged forming a pattern so that a heat transfer capability is created at the front, back and/or rim surface; and the ratio of the distance between projections to the forged disc external radius is lower than 0.15. Furthermore, the present invention also provides a method for manufacturing a rotatable forged disc for a bladed rotor wheel.

Aspects of the disclosure relate to apparatus and methods for producing a downhole electrical component, having steps of providing a non-conductive polymer substrate, establishing an active area on the non-conductive polymer substrate, patterning the active area on the non-conductive polymer substrate with a conductive material through an additive manufacturing process and incorporating the patterned non-conductive polymer substrate into a final arrangement.