A method is provided for manufacturing a component. The method includes connecting a component comprising an internal passage and formed by an additive manufacturing process to a power supply, the component functioning as an anode, connecting a cathode to the power supply, the cathode being disposed in an electrolyte solution, the cathode being positioned externally to the internal passage of the component, contacting the internal passage of the component with the electrolyte solution, and using the power supply, applying a potential difference and current flow between the component and the cathode.

A method for the manufacture of a component having a defined geometry and dimensions is described. In sequence, the steps of the method involve; a) using an additive layer manufacturing process, budding a three-dimensional net shape of the component; b) applying a subtractive surface finishing operation to the product of step a); c) applying a heat treatment to the product of step b) whereby to provide a component to the defined geometry and dimensions.

The present disclosure generally relates to casting molds including a casting core comprising a first metal component and a second metal component. In an aspect, the first metal component has a lower melting point than the second metal component. In another aspect, the second metal component surrounds at least a portion of the first metal component and defines a cavity in the casting core when the first metal component is removed and the second metal component is not removed.

The present disclosure generally relates to casting molds including a casting core comprising a first metal component and a second metal component. In an aspect, the first metal component has a lower melting point than the second metal component. In another aspect, the second metal component surrounds at least a portion of the first metal component and defines a cavity in the casting core when the first metal component is removed and the second metal component is not removed.

The present disclosure generally relates to methods for additive manufacturing (AM) that utilize support leading edge structures in the process of building objects, as well as novel leading edge support structures to be used within these AM processes. The support structure is positioned adjacent the object between the object and a first side of the powder bed. The support structure has a shape that tapers outward in the direction from the first side to the object

The present disclosure relates to a system for using a feedstock to form a three dimensional, hierarchical, porous metal structure with deterministically controlled 3D multiscale porous architectures. The system may have a reservoir for holding the feedstock, the feedstock including a rheologically tuned alloy ink. A printing stage may be used for receiving the feedstock. A processor may be incorporated which has a memory, and which is configured to help carry out an additive manufacturing printing process to produce a three dimensional (3D) structure using the feedstock in a layer-by-layer fashion, on the printing stage. A nozzle may be included for applying the feedstock therethrough onto the printing stage. A de-alloying subsystem may be used for further processing the 3D structure through a de-alloying operation to form a de-alloyed 3D structure having several distinct, differing pore length scales ranging from a digitally controlled macroporous architecture to a nanoporosity introduced by the de-alloying operation.

The present disclosure relates to a system for using a feedstock to form a three dimensional, hierarchical, porous metal structure with deterministically controlled 3D multiscale porous architectures. The system may have a reservoir for holding the feedstock, the feedstock including a rheologically tuned alloy ink. A printing stage may be used for receiving the feedstock. A processor may be incorporated which has a memory, and which is configured to help carry out an additive manufacturing printing process to produce a three dimensional (3D) structure using the feedstock in a layer-by-layer fashion, on the printing stage. A nozzle may be included for applying the feedstock therethrough onto the printing stage. A de-alloying subsystem may be used for further processing the 3D structure through a de-alloying operation to form a de-alloyed 3D structure having several distinct, differing pore length scales ranging from a digitally controlled macroporous architecture to a nanoporosity introduced by the de-alloying operation.

The present disclosure relates to a system for using a feedstock to form a three dimensional, hierarchical, porous metal structure with deterministically controlled 3D multiscale porous architectures. The system may have a reservoir for holding the feedstock, the feedstock including a rheologically tuned alloy ink. A printing stage may be used for receiving the feedstock. A processor may be incorporated which has a memory, and which is configured to help carry out an additive manufacturing printing process to produce a three dimensional (3D) structure using the feedstock in a layer-by-layer fashion, on the printing stage. A nozzle may be included for applying the feedstock therethrough onto the printing stage. A de-alloying subsystem may be used for further processing the 3D structure through a de-alloying operation to form a de-alloyed 3D structure having several distinct, differing pore length scales ranging from a digitally controlled macroporous architecture to a nanoporosity introduced by the de-alloying operation.

Building a complete ship hull, including many internals (bulkhead, holds), as a single, 3D printed device. A Stewart crane is used for gross positioning, while a multitude of beam deposition arms can be used for finer positioning. In a shipbuilding method, this means that the hull, floors, main piping, tanks, quarters, stairs, doorways, etc. can all be printed, in place, as part of a multi-step process.

Aspects of the disclosed technology include an additive manufacturing method including: applying a mixture of metal powder and a carrier agent to a substrate; removing a portion of the carrier agent from the applied mixture; and fusing the metal powder remaining in the applied mixture to the substrate.