Systems and methods are disclosed for fabricating a metal or ceramic component using a 3D printer. An entire 3D printed piece, including both the metal or ceramic component and one or more support structures, is created of a first metal or ceramic material. A sensitization layer is applied to all or part of the 3D printed piece to chemically alter portions of the first metal or ceramic material near the surface making those portions of the material more sensitive to the etching process. The etching process causes the affected material to deplete and separates the component from the support structures without requiring mechanical machining.

The present disclosure relates to custom additively manufactured core structures and the manufacture thereof. In one aspect, a panel for use in a transport structure includes first and second face sheets, and an additively manufactured (AM) core affixed between the first and second face sheets. The AM core is foldable such that at least one portion of the AM core is movable between a folded position and an unfolded position. In another aspect of the disclosure, a method for producing a panel for use in a transport structure includes additively manufacturing a core is disclosed.

Methods and apparatus to identify additively manufactured parts are disclosed. An example apparatus includes a body, formed of layers layered substantially parallel to a base layer, composed of a first material having a first density, a first indicium embedded internally in the body as a void, and a second indicium on an external surface of the body, the second indicium aligning with the first indicium.

A spacecraft panel includes a first skin, a second skin spaced apart from the first skin, and a first truss structure connecting the first skin to the second skin. The first truss structure includes a plurality of truss members, and each truss member is integral with the first skin and the second skin, such that the first skin, the second skin, and the first truss structure collectively form a single monolithic joint-free structure.

In one aspect, additive manufacture techniques are described herein which enable the densification of green articles prior to further article processing. In some embodiments, a method of forming an article comprises providing a powder composition, and forming the powder composition into a green article by one or more additive manufacturing techniques. The green article is contacted with a powder pressure transfer media. The green article and powder pressure transfer media are then subjected to cold isostatic pressing (CIP) or warm isostatic pressing (WIP) at a pressure less than minimum isostatic compaction pressure of the powder pressure transfer media to provide a densified green article.

In one aspect, additive manufacture techniques are described herein which enable the densification of green articles prior to further article processing. In some embodiments, a method of forming an article comprises providing a powder composition, and forming the powder composition into a green article by one or more additive manufacturing techniques. The green article is contacted with a powder pressure transfer media. The green article and powder pressure transfer media are then subjected to cold isostatic pressing (CIP) or warm isostatic pressing (WIP) at a pressure less than minimum isostatic compaction pressure of the powder pressure transfer media to provide a densified green article.

In one aspect, additive manufacture techniques are described herein which enable the densification of green articles prior to further article processing. In some embodiments, a method of forming an article comprises providing a powder composition, and forming the powder composition into a green article by one or more additive manufacturing techniques. The green article is contacted with a powder pressure transfer media. The green article and powder pressure transfer media are then subjected to cold isostatic pressing (CIP) or warm isostatic pressing (WIP) at a pressure less than minimum isostatic compaction pressure of the powder pressure transfer media to provide a densified green article.

Embodiments of bladed rotors and methods for manufacturing bladed rotors are provided herein. The method for manufacturing bladed rotors includes providing a workpiece including a first rotor blade segment. The first rotor blade segment includes a first platform portion on a radially outward end portion of the first rotor blade segment. Further, the method includes forming a second rotor blade segment, by additive manufacturing, removing a side portion of the first platform portion, and removing a side portion of the second rotor blade segment, whereby a second platform portion remains on a radially outward end portion of the second rotor blade segment.

Embodiments of bladed rotors and methods for manufacturing bladed rotors are provided herein. The method for manufacturing bladed rotors includes providing a workpiece including a first rotor blade segment. The first rotor blade segment includes a first platform portion on a radially outward end portion of the first rotor blade segment. Further, the method includes forming a second rotor blade segment, by additive manufacturing, removing a side portion of the first platform portion, and removing a side portion of the second rotor blade segment, whereby a second platform portion remains on a radially outward end portion of the second rotor blade segment.

Disclosed is a method for forming an orthopaedic implant. The method comprises determining one or more parameters of a bone, of a subject, to which the implant is to be attached, and calculating specifications based on parameters. That calculation includes calculating a mechanical property relating to elasticity of the implant, a length of the implant, and positions of two or more fixation locations by which to fix the implant to the bone. The method further comprises forming the implant based on the specifications, wherein each fixation location comprises a longitudinal axis through the implant, and calculating specifications comprises calculating a trajectory for the longitudinal axis of the respective fixation location.