A hybrid method of surface hardening metallic components using a combination of chemical modification achieved through additive manufacturing and/or diffusion-based processing with transformation-based processing using a high energy density heat source. The hybrid process results in increased surface hardness and/or increased average case hardness and/or increased case depth compared to either treatment individually.

Some embodiments relate to additive manufactured articles having passivated surfaces and related methods. The methods may comprise forming a three-dimensional (3D) article by additive manufacturing to obtain an additive manufactured 3D article comprising a magnesium component. The method may further comprise exposing the additive manufactured 3D article to a reactive gas phase comprising a fluorine component. The fluorine component from the reactive gas phase may react with the magnesium component of the additive manufactured 3D article to form a passivation layer at and below a surface of the additive manufacture 3D article.

Some embodiments relate to additive manufactured articles having passivated surfaces and related methods. The methods may comprise forming a three-dimensional (3D) article by additive manufacturing to obtain an additive manufactured 3D article comprising a magnesium component. The method may further comprise exposing the additive manufactured 3D article to a reactive gas phase comprising a fluorine component. The fluorine component from the reactive gas phase may react with the magnesium component of the additive manufactured 3D article to form a passivation layer at and below a surface of the additive manufacture 3D article.

A particulate for an additive manufacturing technique includes a particulate body formed from a particulate material and a coating disposed over particulate body. The coating includes a carbonaceous material that has a reflectivity that is lower than a reflectivity of the particulate material to reduce an energy input requirement of the particulate such that less energy is necessary to fuse the particulate into a layer of an article fabricated using the additive manufacturing technique. A method of making particulate is also disclosed.

Some embodiments relate to additive manufactured articles having coated surfaces and related methods. The methods may comprise forming a three-dimensional (3D) article by additive manufacturing to obtain an additive manufactured 3D article having a monolithic structure that is not capable of construction by machining, and exposing the additive manufactured 3D article to one or more precursor gases to form a coating layer on a surface of the additive manufactured 3D article. The additive manufactured articles may comprise an additive manufactured three-dimensional (3D) body. The additive manufactured 3D body may have a monolithic structure that is not capable of construction by machining. The additive manufactured 3D body may have a coating layer on a surface of the additive manufactured 3D body.

Some embodiments relate to additive manufactured articles having coated surfaces and related methods. The methods may comprise forming a three-dimensional (3D) article by additive manufacturing to obtain an additive manufactured 3D article having a monolithic structure that is not capable of construction by machining, and exposing the additive manufactured 3D article to one or more precursor gases to form a coating layer on a surface of the additive manufactured 3D article. The additive manufactured articles may comprise an additive manufactured three-dimensional (3D) body. The additive manufactured 3D body may have a monolithic structure that is not capable of construction by machining. The additive manufactured 3D body may have a coating layer on a surface of the additive manufactured 3D body.

The various embodiments described herein include methods, devices, and systems for customizing dental care. In one aspect, personalized toothbrush devices are 3-D printed for a plurality of users. A 3-D dental model of a respective user's mouth is obtained, and a configuration for a mouthpiece of a respective personalized toothbrush device is determined. The respective personalized toothbrush device is 3-D printed, and includes a top cleaning tray, a bottom cleaning tray, and a set of cleaning elements, each customized based at least in part on the 3-D dental model of the respective user's mouth. Each personalized toothbrush device is 3-D printed for each respective user of the plurality of users, and is different from every other user's personalized toothbrush device.

Methods, systems, and apparatus, for hybrid additive manufacturing of parts. In one aspect, a method includes providing a workpiece and manufacturing multiple additive layers on a surface of the workpiece. Manufacturing each of the multiple additive layers includes forming one or more formed layers on a surface of the workpiece by depositing a quantity of powder material on a growth surface, the growth surface inclusive of at least one of a first surface of the workpiece and a second surface of a previously formed layer, and applying a first amount of energy to the quantity of powder material to fuse the particles of the powder material into a formed layer fused to the growth surface, where the formed layer includes a formed surface, and further applying a secondary process to a particular area of the formed surface of the one or more formed layers on the workpiece.

An example processing system for processing a part includes: a processing chamber to hold the part to be processed; a plurality of supply reservoir to contain respective processing fluids; an injection system fluidly coupled to the plurality of supply reservoirs; and a controller operatively coupled to the injection system, the controller to: based on the part to be processed, select a processing sequence for processing the part; and control the injection system to execute the selected processing sequence; wherein the processing sequence is selected from: (i) injecting, sequentially, a first volume of a first processing fluid and a second volume of a second processing fluid; and (ii) combining a third volume of a third processing fluid and a fourth volume of a fourth processing fluid to form a combined processing fluid and injecting the combined processing fluid into the processing chamber.

An example processing system for processing a part includes: a processing chamber to hold the part to be processed; a plurality of supply reservoir to contain respective processing fluids; an injection system fluidly coupled to the plurality of supply reservoirs; and a controller operatively coupled to the injection system, the controller to: based on the part to be processed, select a processing sequence for processing the part; and control the injection system to execute the selected processing sequence; wherein the processing sequence is selected from: (i) injecting, sequentially, a first volume of a first processing fluid and a second volume of a second processing fluid; and (ii) combining a third volume of a third processing fluid and a fourth volume of a fourth processing fluid to form a combined processing fluid and injecting the combined processing fluid into the processing chamber.