The invention relates to a manufacturing system and method for manufacturing a part. A negative powder forms a holder suitable to hold particles of a positive powder in proximity to one another. A connection scheme such as heating, the use of pressure and/or a binder, when employed, connects the particles to one another to form the part.

A deployable manufacturing center (DMC) system includes a foundry module containing a metallurgical system configured to convert a raw material into an alloy powder, and an additive manufacturing (AM) module containing an additive manufacturing system configured to form the alloy powder into metal parts. The deployable manufacturing center (DMC) system can also include a machining module containing a machining system configured to machine the metal parts into machined metal parts, and a quality conformance (QC) module containing an inspection and evaluation system configured to inspect and evaluate the metal parts. A process for manufacturing metal parts includes the steps of providing the deployable manufacturing center (DMC) system; deploying the (DMC) system to a desired location; forming an alloy powder from a raw material using the deployable foundry module; and then forming the metal parts from the alloy powder using the additive manufacturing (AM) module.

A deployable manufacturing center (DMC) system includes a foundry module containing a metallurgical system configured to convert a raw material into an alloy powder, and an additive manufacturing (AM) module containing an additive manufacturing system configured to form the alloy powder into metal parts. The deployable manufacturing center (DMC) system can also include a machining module containing a machining system configured to machine the metal parts into machined metal parts, and a quality conformance (QC) module containing an inspection and evaluation system configured to inspect and evaluate the metal parts. A process for manufacturing metal parts includes the steps of providing the deployable manufacturing center (DMC) system; deploying the (DMC) system to a desired location; forming an alloy powder from a raw material using the deployable foundry module; and then forming the metal parts from the alloy powder using the additive manufacturing (AM) module.

A deployable manufacturing center (DMC) system includes a foundry module containing a metallurgical system configured to convert a raw material into an alloy powder, and an additive manufacturing (AM) module containing an additive manufacturing system configured to form the alloy powder into metal parts. The deployable manufacturing center (DMC) system can also include a machining module containing a machining system configured to machine the metal parts into machined metal parts, and a quality conformance (QC) module containing an inspection and evaluation system configured to inspect and evaluate the metal parts. A process for manufacturing metal parts includes the steps of providing the deployable manufacturing center (DMC) system; deploying the (DMC) system to a desired location; forming an alloy powder from a raw material using the deployable foundry module; and then forming the metal parts from the alloy powder using the additive manufacturing (AM) module.

Aspects for implementing 3-D printed metrology feature geometries and detection are disclosed. The apparatus may a measurement device for a 3-D printed component. The component may include a plurality of printed-in metrology features arranged at different feature locations on a surface of the component. The measurement device can be configured to detect the feature locations of the printed-in metrology features and to determine a position or an orientation of the component based on the detected feature locations. In various embodiments, the metrology feature may be a protruding or recessed spherical portion, with the corresponding feature location at the center of the sphere.

Aspects for implementing 3-D printed metrology feature geometries and detection are disclosed. The apparatus may a measurement device for a 3-D printed component. The component may include a plurality of printed-in metrology features arranged at different feature locations on a surface of the component. The measurement device can be configured to detect the feature locations of the printed-in metrology features and to determine a position or an orientation of the component based on the detected feature locations. In various embodiments, the metrology feature may be a protruding or recessed spherical portion, with the corresponding feature location at the center of the sphere.

Provided is a method of manufacturing an impeller assembly, the method including providing an impeller including: a rotary shaft; a base portion radially extending outward from the rotary shaft; and a plurality of blades extending radially outward from the rotary shaft and disposed on the base portion, each of the plurality of blades provided apart from one another in a circumferential direction around the rotary shaft; providing a mold in an area between the plurality of blades; and forming a shroud covering upper portions of the plurality of blades and an upper portion of the mold, wherein the forming the shroud comprises applying a melted metal on the upper portions of the plurality of blades and the upper portion of the mold.

Provided herein are systems, apparatuses and methods for monitoring a three-dimensional printing process. The three-dimensional printing process can be monitored in-situ and/or in real time. Monitoring of the three-dimensional printing process can be non-invasive. A computer control system can be coupled to one or more detectors and signal processing units to adjust the generation of a three-dimensional object that is formed by the three-dimensional printing.

A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.

A method, product, apparatus, and article of manufacture for the application of the Composite Based Additive Manufacturing (CBAM) method to produce objects in metal, and in metal fiber hybrids or composites. The approach has many advantages, including the ability to produce more complex geometries than conventional methods such as milling and casting, improved material properties, higher production rates and the elimination of complex fixturing, complex tool paths and tool changes and, for casting, the need for patterns and tools. The approach works by slicing a 3D model, selectively printing a fluid onto a sheet of substrate material for each layer based on the model, flooding onto the substrate a powdered metal to which the fluid adheres in printed areas, clamping and aligning a stack of coated sheets, heating the stacked sheets to melt the powdered metal and fuse the layers of substrate, and removing excess powder and unfused substrate.