A method of additively manufacturing a monolithic metal article having a three-dimensional shape is disclosed. The method involves forming a preform of the article that includes atomized metal particles bound together by a binder material. The atomized metal particles, more specifically, comprises (1) water atomized metal particles and (2) gas atomized metal particles, plasma atomized metal particles, or a mixture of gas atomized metal particles and plasma atomized metal particles. The water atomized metal particles may be contained in one portion of the preform and the gas and/or plasma atomized metal particles may be contained in another portion of the preform. The method also includes removing at least a portion of the binder material from the preform and sintering the preform to transform the preform into the monolithic metal article.

Disclosed are a system for and a method of manufacturing a three-dimensional (3D) structure. The method may include injecting a fluid with a first pressure toward a surface of a first output layer to form a softening layer in the first output layer, injecting the fluid with a second pressure toward the softening layer to form an uneven structure in the softening layer, the second pressure being higher than the first pressure, and forming a second output layer on the softening layer with the uneven structure.

Three-dimensional structures may be formed on a substrate using a propellant that may decompose to form a gaseous byproduct. At least one overlying shell layer may deform due to volumes of gas between the substrate and the shell layer formed by the gaseous byproduct, thereby forming the three-dimensional structures. Multiple layers of propellant and shell layers may be stacked to multi-layered, three-dimensional structures. Propellant with different concentrations and shell layers with different thicknesses and materials may be used to control the shapes formed when the propellant is decomposed. Alternatively, porous layers may be deposited on a substrate and heated to expand volumes of gas between the substrate and the porous layers, thereby forming three-dimensional structures. The three-dimensional structures may be formed as microlenses in imaging sensor pixels, as it may be desired to form an array of microlenses that vary in size, shape, or curvature across one or more pixels.

Sputtering printheads, additive manufacturing systems comprising the same, and methods for additive manufacturing are provided. Sputtering printheads of the present invention use a plasma to sputter a feedstock material which is directed towards a target. A printhead can include a heater to heat the feedstock to, or near, the material's melting point as it is being sputtered to increase the deposition rate. A convergent nozzle can also increase the deposition rate. Printheads of the present invention are readily reconfigurable such that the same printhead can be used to deposit different materials, such as metals and non-metals, in succession by replacing the feedstock material and making changes to a few settings. Additive manufacturing systems of the present invention can be operated at normal room temperatures and pressure.

Sputtering printheads, additive manufacturing systems comprising the same, and methods for additive manufacturing are provided. Sputtering printheads of the present invention use a plasma to sputter a feedstock material which is directed towards a target. A printhead can include a heater to heat the feedstock to, or near, the material's melting point as it is being sputtered to increase the deposition rate. A convergent nozzle can also increase the deposition rate. Printheads of the present invention are readily reconfigurable such that the same printhead can be used to deposit different materials, such as metals and non-metals, in succession by replacing the feedstock material and making changes to a few settings. Additive manufacturing systems of the present invention can be operated at normal room temperatures and pressure.

A method and associated systems for 3D printing on the surface of an acoustic hologram uses an array of sound-wave emitters to generate a three-dimensional acoustic hologram of an object to be printed. This hologram is composed of acoustic standing waves that exert invisible acoustic radiation forces in three-dimensional space that feel like surfaces of a solid object. The resulting hologram creates a tactile illusion of an object floating in space within a three-dimensional printing area. When a 3D-printing medium is applied to the surface of the hologram, the medium solidifies on the hologram's surface to generate a hollow shell in the shape of the object to be printed.

A method and associated systems for 3D printing on the surface of an acoustic hologram uses an array of sound-wave emitters to generate a three-dimensional acoustic hologram of an object to be printed. This hologram is composed of acoustic standing waves that exert invisible acoustic radiation forces in three-dimensional space that feel like surfaces of a solid object. The resulting hologram creates a tactile illusion of an object floating in space within a three-dimensional printing area. When a 3D-printing medium is applied to the surface of the hologram, the medium solidifies on the hologram's surface to generate a hollow shell in the shape of the object to be printed.

A system and method for manufacturing and authenticating a component is provided. The method includes forming a component having an identifying region that contains two or more materials having different conductivities such that the identifying region generates an eddy current response signature that defines a component identifier of the component. The method further includes interrogating the identifying region of the surface with an eddy current probe to determine the component identifier. The component identifier may be stored in a database as a reference identifier and may be used for authenticating components.

A method for patterning a three-dimensional structure is provided. The method may include providing a substrate, the substrate including the three-dimensional structure, and directing a depositing species from a deposition source to the three-dimensional structure, wherein a layer forms on the three-dimensional structure. The method may further include directing angled ions to the three-dimensional structure from an ion source, wherein the angled ions impinge on a first region of the layer and do not impinge on a second region of the layer. As such, the first region may form a densified layer portion having a first density, and the second region may form an undensified layer portion having a second density, less than the first density.

A method for patterning a three-dimensional structure is provided. The method may include providing a substrate, the substrate including the three-dimensional structure, and directing a depositing species from a deposition source to the three-dimensional structure, wherein a layer forms on the three-dimensional structure. The method may further include directing angled ions to the three-dimensional structure from an ion source, wherein the angled ions impinge on a first region of the layer and do not impinge on a second region of the layer. As such, the first region may form a densified layer portion having a first density, and the second region may form an undensified layer portion having a second density, less than the first density.