In exemplary implementations of this invention, a nozzle sprays foam, layer by layer, to fabricate a fabricated object according to a CAD model, and a subtractive fabrication tool removes material from the fabricated object according to a CAD model. The fabricated object comprises a mold or an interior form. The foam may be low-density, high strength and fast-curing. The foam may be used for large-scale 3D printing. For example, the foam may be used to 3D print molds for walls of homes. The foam molds may be left in place, after casting concrete in the molds, to serve as insulation. Or for example, the foam may be used to 3D print on site an internal form for a large wind turbine blade. The wind turbine blade may then be produced on site by depositing fiberglass on the outside of the internal form.

The disclosure relates to a bio-artificial periosteum based on micropatterning of biomimetic mineralized calcium-phosphorus nanoparticles and a method for manufacturing the same. The method includes: first, a micropatterned biomimetic mineralized calcium-phosphorus nanoparticle layer is manufactured on a surface of an inert substrate; then, an organic polymer is cross-linked and solidified on the micropatterned biomimetic mineralized calcium-phosphorus nanoparticle layer; at last, the inert substrate is removed, so that the bio-artificial periosteum based on micropatterning of biomimetic mineralized calcium-phosphorus nanoparticles is obtained. The bio-artificial periosteum not only simulates the composition of natural bone in material components, but also realizes high degree of biomimesis in micro-nano size in structure. Moreover, the distribution of bone marrow mesenchymal stem cells can be regulated by the bio-artificial periosteum, so that the cells can be effectively defined on a surface of calcium-phosphorus particle micropattern and a high degree of ordered alignment thereof can be realized.

A casting mold apparatus includes a unitary ceramic core including: an outer skin defining an outer surface; and an internal support structure disposed inside the outer skin, the internal support structure defining a plurality of voids configured to admit fluid to the core.

A composite core die includes a reusable core die; and a disposable core die. The disposable core die is in physical communication with the reusable core die and surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.

In exemplary implementations of this invention, a nozzle sprays foam, layer by layer, to fabricate a fabricated object according to a CAD model, and a subtractive fabrication tool removes material from the fabricated object according to a CAD model. The fabricated object comprises a mold or an interior form. The foam may be low-density, high strength and fast-curing. The foam may be used for large-scale 3D printing. For example, the foam may be used to 3D print molds for walls of homes. The foam molds may be left in place, after casting concrete in the molds, to serve as insulation. Or for example, the foam may be used to 3D print on site an internal form for a large wind turbine blade. The wind turbine blade may then be produced on site by depositing fiberglass on the outside of the internal form.

A process for making a layered multi-material structural element having controlled mechanical failure characteristics. The process includes the steps of: supplying a cementitious layer and forming a polymer layer on the cementitious layer by additive manufacture such that the polymer layer has a first thickness and the cementitious layer has a second thickness, wherein the polymer layer comprises a polymer and the cementitious layer comprises a cementitious material; and allowing the polymer from the polymer layer to suffuse into the cementitious layer for a period of time to obtain a suffused zone in the cementitious layer such that the suffused zone has a third thickness that is less than half the second thickness.

This disclosure concerns use of additive manufacturing, such as 3D printing, in construction. Specifically, this disclosure concerns manufacturing of building elements using 3D printing. A method for manufacturing concrete elements for construction of buildings is also provided wherein concrete elements comprise regions of a concrete material and regions of a filler material. The disclosed method comprises at least the steps of forming a mold by printing mold walls, the mold walls delimiting a plurality of regions in the mold, pouring one of the concrete and filler materials in at least one of the regions in the mold, leaving at least one other region empty, removing at least a part of the mold walls, and pouring the other of the concrete and filler materials in at least one empty region.

The preparation of ceramic matrix composite (CMCs) is disclosed in which a ceramic matrix composite (CMC) preform is made with one or more integrated polymer core inserts made of a fugitive material containing polyvinyl butyral. The preform with integrated polymer core inserts to a heat treatment to remove the one or more polymer core inserts (e.g., by melting or burning). Removal of the polymer core inserts forms one or more internal cavities within the composite, which can then be subjected to densification.

This disclosure concerns use of additive manufacturing, such as 3D printing, in construction. Specifically, this disclosure concerns manufacturing of building elements using 3D printing. A method for manufacturing concrete elements for construction of buildings is also provided wherein concrete elements comprise regions of a concrete material and regions of a filler material. The disclosed method comprises at least the steps of forming a mold by printing mold walls, the mold walls delimiting a plurality of regions in the mold, pouring one of the concrete and filler materials in at least one of the regions in the mold, leaving at least one other region empty, removing at least a part of the mold walls, and pouring the other of the concrete and filler materials in at least one empty region.

A method for forming a hole within a ceramic matrix composite component includes forming a first core portion for a ceramic matrix composite component; embedding a hollow member into the first core portion at a desired location; wrapping the first core portion with a first ceramic matrix composite material; inserting a rod through the hollow member and into the first core portion; removing the hollow member; assembling a second core portion to the first core portion such that the rod extends into the second core portion; and wrapping the first core portion and the second core portion with a second ceramic matrix composite material.