A method of forming an article including: contacting a fugitive tool with a powdered parent material; densifying the powdered material; and destructively removing the fugitive tool. A coating of a different material may be formed against the parent material using a similar approach.

A method of forming an article including: contacting a fugitive tool with a powdered parent material; densifying the powdered material; and destructively removing the fugitive tool. A coating of a different material may be formed against the parent material using a similar approach.

In an example implementation, a sintering system includes a support structure in a sintering furnace to support a token green object during a sintering process. The system includes wires installed into the furnace and through the support structure to contact the object. An impedance meter is operatively coupled to the wires to determine electrical impedance of the object during the sintering process.

An additively manufactured (AM) object may include a body including an opening in an exterior surface thereof, the opening having a shape and a first area at the exterior surface of the body. A mask may be positioned over the opening. The mask has the shape of the opening and a second area that is larger than the first area so as to overhang the exterior surface of the body about the opening. A plurality of support ligaments couple to the mask and the exterior surface of the body at a location adjacent to the opening to support a portion of the mask. A coating can be applied to the object, and the mask removed. The final AM object includes a plurality of ligament elements extending from the exterior surface of the body and through the coating adjacent the opening, each ligament element at least partially surrounded by the coating.

A method for heat treating a powder part preform including a titanium-based alloy, wherein the method includes the heat treatment of the preform in a furnace at a predetermined temperature, wherein the preform is on a holder during the heat treatment, wherein the holder includes a zirconium-based alloy having a zirconium content greater than or equal to 95% by weight, wherein the holder material has a melting temperature higher than the predefined temperature of the heat treatment, and wherein an anti-diffusion barrier is arranged between the preform and the holder in order to prevent welding of the preform to the holder.

A method for heat treating a powder part preform including a titanium-based alloy, wherein the method includes the heat treatment of the preform in a furnace at a predetermined temperature, wherein the preform is on a holder during the heat treatment, wherein the holder includes a zirconium-based alloy having a zirconium content greater than or equal to 95% by weight, wherein the holder material has a melting temperature higher than the predefined temperature of the heat treatment, and wherein an anti-diffusion barrier is arranged between the preform and the holder in order to prevent welding of the preform to the holder.

Improved formulations of an interface material are described. These formulations may, in at least some cases, match and/or accommodate dimensional changes in the part and/or support structure throughout thermal processing (e.g., debind and sintering, or sintering only). Furthermore, these formulations may also maintain the property of resisting bonding between the interface and the part and/or support structure while also maintaining a physical separation between the part and support structure. In some cases, an improved interface material may accommodate strain associated with the shrinkage of a part (and optionally support structure) during sintering while also minimally impacting the ability of the part (and optionally support structure) to shrink or otherwise change in dimension. In some cases, the interface material may include one or more fugitive phases that are removed during thermal processing (e.g., through pyrolysis of the fugitive phase(s)).

Improved formulations of an interface material are described. These formulations may, in at least some cases, match and/or accommodate dimensional changes in the part and/or support structure throughout thermal processing (e.g., debind and sintering, or sintering only). Furthermore, these formulations may also maintain the property of resisting bonding between the interface and the part and/or support structure while also maintaining a physical separation between the part and support structure. In some cases, an improved interface material may accommodate strain associated with the shrinkage of a part (and optionally support structure) during sintering while also minimally impacting the ability of the part (and optionally support structure) to shrink or otherwise change in dimension. In some cases, the interface material may include one or more fugitive phases that are removed during thermal processing (e.g., through pyrolysis of the fugitive phase(s)).

In one example, a 3D printing system includes a support structure generator to identify a breakaway support to temporarily support part of the object, to design a wedge shaped groove between a portion of the object and the support, the groove ending at a line along which the support intersects the object, and to generate a digital object model that includes the support and the groove. The system also includes a 3D printer to print the object, support and groove based on the object model.

In one example, a 3D printing system includes a support structure generator to identify a breakaway support to temporarily support part of the object, to design a wedge shaped groove between a portion of the object and the support, the groove ending at a line along which the support intersects the object, and to generate a digital object model that includes the support and the groove. The system also includes a 3D printer to print the object, support and groove based on the object model.