Techniques are disclosed for fabricating multi-part assemblies. In particular, by forming release layers between features such as bearings or gear teeth, complex mechanical assemblies can be fabricated in a single additive manufacturing process.

A method for manufacture of a complex component includes construction of the component from a metal material in an additive manufacturing method with at least one cavity segment that has a cavity open on at least one side and defined by an interior surface of the component, formation of an auxiliary electrode during construction of the component, formation of one or a plurality of supporting structures that connect the auxiliary electrode to the interior surface of the component during the construction of the component, electrical insulation of the auxiliary electrode from the interior surface by separating the supporting structures from the interior surface or from the auxiliary electrode, and performance of an electro-polishing of the interior surface in an electrolyte bath by connecting the component and the auxiliary electrode to different poles of an electric voltage source.

A method for manufacture of a complex component includes construction of the component from a metal material in an additive manufacturing method with at least one cavity segment that has a cavity open on at least one side and defined by an interior surface of the component, formation of an auxiliary electrode during construction of the component, formation of one or a plurality of supporting structures that connect the auxiliary electrode to the interior surface of the component during the construction of the component, electrical insulation of the auxiliary electrode from the interior surface by separating the supporting structures from the interior surface or from the auxiliary electrode, and performance of an electro-polishing of the interior surface in an electrolyte bath by connecting the component and the auxiliary electrode to different poles of an electric voltage source.

A three-dimensional (3D) printing method and apparatus are disclosed for freeform fabrication of metal articles. 3D printed articles are formed from a build material comprising metal powder(s), polymer(s), and solvent(s). A coagulation agent, such as a nebulized non-solvent, is disposed onto/about the build material during 3D printing to cause at least partial solidification of the build material to form a green body structure. Multiple build materials can be mixed at a variable ratio to achieve a composition gradient through the green body structure. The 3D printed green body structure can be heated to remove some or all of the polymer, solvent, and/or for debinding. The debinded green body structure can be sintered at a specific sintering temperature or over a temperature gradient, for a period of time, in accordance with the sintering properties of the particular metal powder in the debinded green body structure, to form a finished metal part.

A three-dimensional (3D) printing method and apparatus are disclosed for freeform fabrication of metal articles. 3D printed articles are formed from a build material comprising metal powder(s), polymer(s), and solvent(s). A coagulation agent, such as a nebulized non-solvent, is disposed onto/about the build material during 3D printing to cause at least partial solidification of the build material to form a green body structure. Multiple build materials can be mixed at a variable ratio to achieve a composition gradient through the green body structure. The 3D printed green body structure can be heated to remove some or all of the polymer, solvent, and/or for debinding. The debinded green body structure can be sintered at a specific sintering temperature or over a temperature gradient, for a period of time, in accordance with the sintering properties of the particular metal powder in the debinded green body structure, to form a finished metal part.

A heat-resistant alloy contains at least one element selected from a group consisting of Al, Ti, Ni, Cr, and Mo, O, and Y, and a ratio of a content of Y in terms of mass to a content of O in terms of mass is 0.5 or greater and 100 or less.

A heat-resistant alloy contains at least one element selected from a group consisting of Al, Ti, Ni, Cr, and Mo, O, and Y, and a ratio of a content of Y in terms of mass to a content of O in terms of mass is 0.5 or greater and 100 or less.

A 3D-printed reflective optic providing very high specific stiffness through the utilization of a hollow shelled design, with closed back, filled with high-stiffness internal volumetric space-filling open-cell lattice structures. High-stiffness, structurally-integrated, sacrificial structures are also included for the purposes of reduction or elimination of tooling during post-processing operations.

A 3D-printed reflective optic providing very high specific stiffness through the utilization of a hollow shelled design, with closed back, filled with high-stiffness internal volumetric space-filling open-cell lattice structures. High-stiffness, structurally-integrated, sacrificial structures are also included for the purposes of reduction or elimination of tooling during post-processing operations.

A system for forming a product with different size particles is disclosed. The system comprises at least one print head region configured to retain a first group of print heads configurable to additively print at least a first portion of the product with a first material and a second group of print heads configurable to additively print at least a second portion of the product with a second material. The described system may also comprise a processor configured to regulate the first group of print heads and the second group of print heads to distribute the first material and the second material. A method of making an object by ink jet printing using the disclosed system is also disclosed.