Systems and methods for generating molecular dynamic graded lattice structures that can be used as infill for additively manufactured articles. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.

A method of manufacturing a 3D modeled object, includes modeling including applying a modeling solution to powder laid in layers, hardening the powder to which the modeling solution applied to form modeling layers, and sequentially stacking the modeling layers to form a 3D modeled object; and immersing the 3D modeled object modeled at the modeling in a removal solution to remove the powder to which the modeling solution is not applied. At the modeling, the modeling solution is applied such that a density of the modeling solution in an inside of the 3D modeled object is smaller than a density of the modeling solution in a surface of the 3D modeled object and an area of the powder to which the modeling solution is applied and an area of the powder to which the modeling solution is not applied are alternate in the inside of the 3D modeled object.

A method of manufacturing a 3D modeled object, includes modeling including applying a modeling solution to powder laid in layers, hardening the powder to which the modeling solution applied to form modeling layers, and sequentially stacking the modeling layers to form a 3D modeled object; and immersing the 3D modeled object modeled at the modeling in a removal solution to remove the powder to which the modeling solution is not applied. At the modeling, the modeling solution is applied such that a density of the modeling solution in an inside of the 3D modeled object is smaller than a density of the modeling solution in a surface of the 3D modeled object and an area of the powder to which the modeling solution is applied and an area of the powder to which the modeling solution is not applied are alternate in the inside of the 3D modeled object.

Systems and methods for generating molecular dynamic graded lattice structures that can be used as infill for additively manufactured articles. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.

Systems and methods for generating molecular dynamic graded lattice structures that can be used as infill for additively manufactured articles. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.

A fuel cell may include a first fuel cell bipolar plate defining an air layer, a second fuel cell bipolar plate defining a hydrogen layer, and a coolant layer defined by the air layer and the hydrogen layer. A permeable support infill structure, composed of sintered thermally conductive powder particles, is arranged at the cooling layer to prevent flow blockage at the coolant layer, define a thermally conductive path between the air layer and the hydrogen layer, and facilitate coolant flow through the permeable support infill structure.

A fuel cell may include a first fuel cell bipolar plate defining an air layer, a second fuel cell bipolar plate defining a hydrogen layer, and a coolant layer defined by the air layer and the hydrogen layer. A permeable support infill structure, composed of sintered thermally conductive powder particles, is arranged at the cooling layer to prevent flow blockage at the coolant layer, define a thermally conductive path between the air layer and the hydrogen layer, and facilitate coolant flow through the permeable support infill structure.

A method for manufacturing an austenitic stainless steel workpiece including the following successive steps: 1) providing a powder and sintering the powder to form a sintered alloy with an austenitic structure; the alloy having a nitrogen content greater than or equal to 0.1% by weight, 2) treating the sintered alloy to transform the austenitic structure into a ferritic structure or ferrite+ austenite two-phase structure on a surface layer of the alloy, 3) treating the sintered alloy to transform the ferritic or ferrite+ austenite two-phase structure obtained in step 2) into an austenitic structure and, after cooling, forming the workpiece which, on the layer subjected to the transformations in steps 2) and 3), has a density higher than that of the core of the workpiece. The present description also relates to the workpiece obtained by the method which has a very dense surface layer (≥99%).

A build plate includes a surface that defines at least one opening configured for disposal of a proximal portion of a screw shaft. The proximal portion is formed by a first manufacturing method and defines a distal face. The proximal portion is connected with the surface in a configuration to orient the distal face for forming a distal portion of the screw shaft thereon by a second manufacturing method that includes an additive manufacturing apparatus. In some embodiments, systems, spinal constructs, surgical instruments and methods are disclosed.

A build plate includes a surface that defines at least one opening configured for disposal of a proximal portion of a screw shaft. The proximal portion is formed by a first manufacturing method and defines a distal face. The proximal portion is connected with the surface in a configuration to orient the distal face for forming a distal portion of the screw shaft thereon by a second manufacturing method that includes an additive manufacturing apparatus. In some embodiments, systems, spinal constructs, surgical instruments and methods are disclosed.