Cutters for a downhole drill bit can be formed by providing a catalyst-free synthesized polycrystalline diamond (PCD) having a cross-sectional dimension of at least 8 millimeters; providing a substrate comprising tungsten carbide; and attaching the synthesized PCD to the substrate comprising tungsten carbide to form a PDC cutter.

A microwave printing device comprising an inlet for a filament 1 of an electrically conductive material, an outlet for the filament and a microwave heating device 4 for heating the filament 1 by means of microwave radiation. The microwave heating device 4 comprises at least one coaxial resonator. The coaxial resonator is formed by an outer conductor, which forms a cavity 11, and a coaxial inner conductor. The coaxial resonator also comprises a microwave radiation input for coupling in microwave radiation. The filament 1 preferably forms the inner conductor or part of the inner conductor of the resonator. A system for the additive manufacture of moulds, comprising the microwave printing device, and a process for the additive manufacture of moulds with the aid of the microwave printing device.

A microwave printing device comprising an inlet for a filament 1 of an electrically conductive material, an outlet for the filament and a microwave heating device 4 for heating the filament 1 by means of microwave radiation. The microwave heating device 4 comprises at least one coaxial resonator. The coaxial resonator is formed by an outer conductor, which forms a cavity 11, and a coaxial inner conductor. The coaxial resonator also comprises a microwave radiation input for coupling in microwave radiation. The filament 1 preferably forms the inner conductor or part of the inner conductor of the resonator. A system for the additive manufacture of moulds, comprising the microwave printing device, and a process for the additive manufacture of moulds with the aid of the microwave printing device.

Provided is a method for producing a metal solid, the method being capable of easily producing a metal solid. A method for producing a metal solid, the method comprising covering at least a portion of the periphery of a metal powder with a high-melting-point material having a melting point higher than the melting point of the metal powder; and irradiating the metal powder, at least a portion of the periphery of which is covered with the high-melting-point material, with microwaves to heat the metal powder, thereby sintering or melt-solidifying the metal powder.

Additive manufacturing systems are disclosed. The systems may include a build platform, and at least one magnet positioned adjacent the build platform. The magnet(s) may be configured to manipulate a magnetic powder material positioned on the build platform to form a pre-sintered component having a first geometry. The system may also include at least one sprayer nozzle positioned adjacent the build platform, where the at least one sprayer nozzle may be configured to coat the pre-sintered component formed from the magnetic powder material with a binder material. Additionally, the system may include at least one radiant energy component positioned adjacent the build platform. The radiant energy component(s) may be configured to sinter the pre-sintered component to form a sintered component having a second geometry identical to the first geometry of the pre-sintered component.

Additive manufacturing systems are disclosed. The systems may include a build platform, and at least one magnet positioned adjacent the build platform. The magnet(s) may be configured to manipulate a magnetic powder material positioned on the build platform to form a pre-sintered component having a first geometry. The system may also include at least one sprayer nozzle positioned adjacent the build platform, where the at least one sprayer nozzle may be configured to coat the pre-sintered component formed from the magnetic powder material with a binder material. Additionally, the system may include at least one radiant energy component positioned adjacent the build platform. The radiant energy component(s) may be configured to sinter the pre-sintered component to form a sintered component having a second geometry identical to the first geometry of the pre-sintered component.

A method for inspection of additive manufactured parts and monitoring operational performance of an additive manufacturing apparatus is provided. The method includes a heating step for heating an area of a build platform on which at least one part is built by the additive manufacturing apparatus. An obtaining step is used for obtaining, in real-time during an additively manufactured build process, a thermographic scan of the area of the build platform. An evaluating step evaluates, by a processor, the thermographic scan. A determining step determines, based on the evaluating, whether an operational flaw with the additive manufacturing apparatus has occurred or a defect in the at least one part has occurred.

The present invention belongs to the technical field related to additive manufacturing, and provides a multi-field composite-based additive manufacturing device and method. The device comprises a powder delivery adjustment module, a sound field control module, a microwave field/thermal field control module and a microprocessor. The powder delivery adjustment module, the sound field control module and the microwave field/thermal field control module are respectively connected to the microprocessor; the powder delivery adjustment module comprises a raw material dispersion chamber, and the raw material dispersion chamber is provided within a forming cavity formed by a housing; the sound field control module is also provided within the forming cavity and is located below the raw material dispersion chamber; the microwave field/thermal field control module comprises a plurality of microwave generators provided in the forming cavity, the plurality of microwave generators are respectively located at two sides of a forming area.

The present invention belongs to the technical field related to additive manufacturing, and provides a multi-field composite-based additive manufacturing device and method. The device comprises a powder delivery adjustment module, a sound field control module, a microwave field/thermal field control module and a microprocessor. The powder delivery adjustment module, the sound field control module and the microwave field/thermal field control module are respectively connected to the microprocessor; the powder delivery adjustment module comprises a raw material dispersion chamber, and the raw material dispersion chamber is provided within a forming cavity formed by a housing; the sound field control module is also provided within the forming cavity and is located below the raw material dispersion chamber; the microwave field/thermal field control module comprises a plurality of microwave generators provided in the forming cavity, the plurality of microwave generators are respectively located at two sides of a forming area.

A method of forming an article comprises forming a feed material around one or more shapeholders and sintering the feed material and the one or more shapeholders to form a sintered article comprising the one or more shapeholders in a base material. The sintered article is exposed to a solvent to remove the one or more shapeholders from the base material. Additional methods are disclosed, as well as articles including one or more microchannels exhibiting a diameter of from about 5 m to about 10 mm.