Embodiments relate to a method for forming a three-dimensional structure. The method includes determining one or more locations for positioning a sensing device based on structural coordinate information relating to a three-dimensional structure to be formed. The method further includes forming a portion of the three-dimensional structure based on the structural coordinate information. The method further includes positioning the sensing device at a location of the one or more locations.

A method for manufacturing a sintered product from a three-dimensional object as a solution includes: a preparation step S11, a degreasing step S12, and a sintering step S13. In S11, a multilayer made of an ink containing inorganic particles and an organic material is formed to prepare a three-dimensional object. S12 includes: a first degreasing step of heating the three-dimensional object under an inert gas atmosphere at a first average degreasing temperature (T1) for a first heating time to degrease the organic material; and a second degreasing step of heating the three-dimensional object degreased in the first degreasing step, under an inert gas atmosphere at a second average degreasing temperature (T2) higher than Ti for a second heating time to degrease the organic material. In S13, the three-dimensional object degreased in the second degreasing step is sintered at an average sintering temperature higher than T2 to obtain a sintered product.

A three-dimensional device is fabricated in a layer-by-layer approach using a support material. The support material is deposited in a liquid form on a surface, hardened by cooling or ultraviolet (UV) curing, and selectively ablated to create an area within which the desired structure of the device will be formed. Active material is deposited into this area, and the layer-by-layer process repeated until the three-dimensional device has been completed. Thereafter, any remaining support material is removed by water or other solvent.

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.

Methods, systems, and devices for precision locating additively manufactured components for assembly and/or post processing manufacturing are provided for herein. In some embodiments, at least one component can be additively manufactured to include one or more kinematic features on one or more surfaces of the component. The kinematic feature(s) can be configured to engage complementary kinematic feature(s) formed in a second component so the two components can form an assembly. Alternatively, the kinematic feature(s) can be configured to engage complementary kinematic feature(s) associated with a post-processing machine such that the one or more post-processing actions can be performed on the component after the component is precisely located with respect to the machine by way of the kinematic features of the component and associated with the machine. A variety of systems and methods that utilize kinematic features are also provided.

A torque bar manufactured by an additive manufacturing process is provided. The torque bar may include a torque bar body made of more than one metallic material. The torque bar may also include a geometry that comprises one or more voids and one or more webs, as well as a varied geometry in the direction of a longitudinal axis. The torque bars can exhibit characteristics, such as vibration damping, tuned stiffness, and tuned bending resistance in order to enhance dynamic stability.

An additive manufactured multi-portion article includes a first portion of an article manufactured by a first additive manufacturing process; and a second portion of the article manufactured by a second additive manufacturing process different than the first additive manufacturing process, the second portion attached to the first portion.

A monolithic lead separator includes a primary lead tube defining a primary channel, a plurality of secondary lead tubes formed monolithically with the primary lead tube, and an instrumentation lead splitter. A cap is positioned in an aperture in the instrumentation lead splitter in a fluid-tight manner. Each of the secondary channels intersects the primary channel. The instrumentation lead splitter is situated at the intersection of the primary channel and the secondary channels.

A method for producing a catalyst or catalyst precursor is described including: applying a slurry of a particulate catalyst compound in a carrier fluid to an additive layer manufactured support structure to form a slurry-impregnated support, and drying and optionally calcining the slurry-impregnated support to form a catalyst or catalyst precursor. The mean particle size (D50) of the particulate catalyst compound in the slurry is in the range 1-50 μm and the support structure has a porosity ≧0.02 ml/g.

A method for producing a catalyst or catalyst precursor is described including: applying a slurry of a particulate catalyst compound in a carrier fluid to an additive layer manufactured support structure to form a slurry-impregnated support, and drying and optionally calcining the slurry-impregnated support to form a catalyst or catalyst precursor. The mean particle size (D50) of the particulate catalyst compound in the slurry is in the range 1-50 μm and the support structure has a porosity ≧0.02 ml/g.