A method of fabricating a burner element for an abatement apparatus is disclosed. The method comprises: injection moulding a charge comprising metal particles and a flow compound into a mould defining the burner element to produce a moulded burner element; and sintering the moulded burner element. In this way, injection moulding is used to produce the burner element, which provides far more flexibility regarding the design and properties of the burner element and avoids the necessity of incorporating a perforated support into the burner element. This allows burner elements of more intricate design to be produced, as well as burner elements which are thinner than those produced using existing techniques, which increases the volume of a combustion chamber defined by that burner element for any external burner element size, which in turn increases the amount of effluent gas that can be treated for any burner size.

A downhole component including a first portion; a second portion; a controlled failure structure between the first portion and second portion. A method for improving efficiency in downhole components.

A downhole component including a first portion; a second portion; a controlled failure structure between the first portion and second portion. A method for improving efficiency in downhole components.

A medical implant which comprises a porous lattice is fabricated with additive manufacturing techniques such as direct metal laser sintering. A CAD model of the porous lattice is created by defining a trimming volume and merging some lattice elements with adjacent solid substrate.

A method for producing an additively manufactured, graded composite transition joint (AM-GCTJ) includes preparing a grating or lattice pattern from a first alloy A; the grating or lattice pattern includes pores in the grating or lattice patterns. The grating pattern is built from a first end to a second end being denser on the first end than on second end, and gradually reduces density by increasing the pore size and/or reducing density of the grating or lattice pattern; adding a second alloy B powder to the second end of grating or lattice pattern. The second alloy B powder is filled towards the first end. A composite is formed of first alloy A and second alloy B powder in the AM-GCTJ. The composite is subjected to hot isotropic pressing (HIP) to densify the composite. The second alloy B is graduated from the first end to the second end O of AM-GCTJ.

A method for producing an additively manufactured, graded composite transition joint (AM-GCTJ) includes preparing a grating or lattice pattern from a first alloy A; the grating or lattice pattern includes pores in the grating or lattice patterns. The grating pattern is built from a first end to a second end being denser on the first end than on second end, and gradually reduces density by increasing the pore size and/or reducing density of the grating or lattice pattern; adding a second alloy B powder to the second end of grating or lattice pattern. The second alloy B powder is filled towards the first end. A composite is formed of first alloy A and second alloy B powder in the AM-GCTJ. The composite is subjected to hot isotropic pressing (HIP) to densify the composite. The second alloy B is graduated from the first end to the second end O of AM-GCTJ.

A method of compensating for sintering warpage due to powder spreading density variations in binder jetting additive manufacturing, including receiving an initial design file defining an object geometry, representing the object geometry as a part mesh and filling the mesh with a grid of voxels to create a voxel grid, each voxel having at least one shrinkage coefficient. For each voxel, determining a distortion factor caused by a powder density variation induced during a powder spreading process and adjusting the at shrinkage coefficient of each voxel according to its respective distortion factor. Next, a shrinkage of the grid of voxels is simulated according to a sintering process. A negative compensation is applied to the voxel grid, according to the simulated shrinkage of the grid of voxels, to form a compensated voxel grid. Lastly, the change in the voxel grid is mapped to the compensated voxel grid onto the part mesh to create a pre-processed compensated part mesh.

A method of compensating for sintering warpage due to powder spreading density variations in binder jetting additive manufacturing, including receiving an initial design file defining an object geometry, representing the object geometry as a part mesh and filling the mesh with a grid of voxels to create a voxel grid, each voxel having at least one shrinkage coefficient. For each voxel, determining a distortion factor caused by a powder density variation induced during a powder spreading process and adjusting the at shrinkage coefficient of each voxel according to its respective distortion factor. Next, a shrinkage of the grid of voxels is simulated according to a sintering process. A negative compensation is applied to the voxel grid, according to the simulated shrinkage of the grid of voxels, to form a compensated voxel grid. Lastly, the change in the voxel grid is mapped to the compensated voxel grid onto the part mesh to create a pre-processed compensated part mesh.

A method for producing a metal shaped article having a porous structure includes a mold formation step of forming a mold having a plurality of columnar structures extending from a substrate by performing a resin material supply step of supplying a liquid containing a resin material to a plurality of places of the substrate at intervals in two directions crossing each other, and a curing step of curing the liquid, a sintering target material supply step of supplying a sintering target material to the mold, a removal step of removing the substrate, a degreasing step of degreasing the columnar structures, and a sintering step of sintering the sintering target material.

A method for producing a metal shaped article having a porous structure includes a mold formation step of forming a mold having a plurality of columnar structures extending from a substrate by performing a resin material supply step of supplying a liquid containing a resin material to a plurality of places of the substrate at intervals in two directions crossing each other, and a curing step of curing the liquid, a sintering target material supply step of supplying a sintering target material to the mold, a removal step of removing the substrate, a degreasing step of degreasing the columnar structures, and a sintering step of sintering the sintering target material.