The present invention disclosed a method of producing a three-dimensional porous tissue in-growth structure. The method includes the steps of depositing a first layer of metal powder and scanning the first layer of metal powder with a laser beam to form a portion of a plurality of predetermined unit cells. Depositing at least one additional layer of metal powder onto a previous layer and repeating the step of scanning a laser beam for at least one of the additional layers in order to continuing forming the predetermined unit cells. The method further includes continuing the depositing and scanning steps to form a medical implant.

Process for synthesizing a material, the process including the steps consisting in: a) providing a plurality of powders including: at least one powder including lithium, at least one powder including, for more than 95.0% of its mass, a transition metal chosen from titanium, cobalt, manganese, nickel, niobium, tin, iron and mixtures thereof, and at least one powder including, for more than 95.0% of its mass, a chalcogen element chosen from sulfur, selenium, tellurium and mixtures thereof, b) preparing a particulate mixture by mixing all the powders of the plurality or by mixing one of the powders of the plurality with a milled material obtained by milling a particulate assembly formed by mixing at least two of the other powders of the plurality, and milling the particulate mixture to form the material.

A method of making a projectile apparatus is provided that includes making one or components of the apparatus using an additive manufacture technique such as 3-D printing or laser-aided additive manufacture. The projectile apparatus can have a projectile, a propellant, and one or more optional components such as a wading, a sabot, and an intermediary device. The projectile can be fired through a barrel having a smooth bore. Additive manufacture methods can be used that involve forming components from superalloys having nanoparticles incorporated therein. The projectile apparatus can convert gas pressure or gas velocity into a high rate of projectile spin. The projectile has long-range accuracy due to a high or sustainable velocity and high rate of spin.

A Ti-6Al-4V titanium powder alloy composition having enhanced strength resulting from the addition of one or more of the following elements without requiring an increase in oxygen content: Aluminum Iron Nitrogen Carbon

The composition may also be used for Ti-6Al-4V titanium alloy starting bar stock.

A method for manufacturing a titanium based product includes the following steps. The first step is providing a titanium hydride ingot. The next step is pre-sintering the titanium hydride ingot to dehydrogenate the titanium hydride ingot according to a first temperature control mode, so as to form a titanium ingot. The next step is machining the titanium ingot to form a titanium semi-product having a desired shape. The last step is post-sintering the titanium semi-product according to a second temperature control mode that is different from the first temperature control mode, so as to form the titanium based product.

There is provided a method of manufacturing a component. The method comprises creating a preform from a material using additive manufacturing and heat treating the preform at a heating temperature to modify the microstructure of the material. The preform is geometrically unconstrained during the step of heat treating. The method then comprises compressive forming the preform into a predefined arrangement to create the component wherein the step of compressive forming is effective to close pores and diffusively bond the material. The material may then be geometrically constrained as it is cooled, for example within the die used for compressive forming.

The invention relates to a method for producing a composite material consisting of a metal and ceramic alloy, comprising steps of: producing a mixture of metal powder and ceramic powder, the particle size of the metal powder being micrometric and the particle size of the ceramic powder being nanometric; and exposing said mixture to a focused energy source that selectively fuses part of a bed of said powder mixture.

A projectile apparatus is provided that includes a projectile, a propellant, and optional components such as a wading, a sabot, and an intermediary device. The projectile can be fired through a barrel having a smooth bore. A sabot is provided that can include molded features, for example, a base portion and a plurality of petal portions defining, in-part, a volume for accommodating a projectile. The sabot and wadding can include molded features that control and direct gases produced by the propellant. The apparatus can convert gas pressure or gas velocity into a high rate of projectile spin. The projectile has long-range accuracy due to a high or sustainable velocity and high rate of spin.

In one aspect, methods of making freestanding metal matrix composite articles and alloy articles are described. A method of making a freestanding composite article described herein comprises disposing over a surface of the temporary substrate a layered assembly comprising a layer of infiltration metal or alloy and a hard particle layer formed of a flexible sheet comprising organic binder and the hard particles. The layered assembly is heated to infiltrate the hard particle layer with metal or alloy providing a metal matrix composite, and the metal matrix composite is separated from the temporary substrate. Further, a method of making a freestanding alloy article described herein comprises disposing over the surface of a temporary substrate a flexible sheet comprising organic binder and powder alloy and heating the sheet to provide a sintered alloy article. The sintered alloy article is then separated from the temporary substrate.

A method of titanium wire additive manufacturing is disclosed. The method may comprise mixing a plurality of powdered metals comprising titanium, iron, vanadium, and aluminum to produce a powder blend, sintering the powder blend to form a billet, performing a wire forming operation to produce a worked wire, heat treating the worked wire to produce a heat treaded wire, loading the heat treated wire into a wirefeed additive manufacturing machine, and producing a metallic component from the heat treated wire. The titanium may be a titanium hydride powder.