According to one aspect, the present disclosure provides a system for manufacturing transition structures including fiber threads embedded within a metal component. The system may include a supply of base sheet metal. The system may include a conveyor supported on a plurality of rollers and configured to move the base sheet metal in a production direction. The system may include a plurality of stages arranged in the production direction. Each stage may include a channel forming device configured to form a channel in the base sheet metal, a fiber inserting device configured to insert a portion of a fiber material into the channel, and one or more ultrasonic welders configured to consolidate a layer of metal foil over the fiber. The disclosure includes methods of using the system to produce transition structures and reinforced components.

According to one aspect, the present disclosure provides a system for manufacturing transition structures including fiber threads embedded within a metal component. The system may include a supply of base sheet metal. The system may include a conveyor supported on a plurality of rollers and configured to move the base sheet metal in a production direction. The system may include a plurality of stages arranged in the production direction. Each stage may include a channel forming device configured to form a channel in the base sheet metal, a fiber inserting device configured to insert a portion of a fiber material into the channel, and one or more ultrasonic welders configured to consolidate a layer of metal foil over the fiber. The disclosure includes methods of using the system to produce transition structures and reinforced components.

A three-dimensional (3D) print engine includes (A) a plurality of walls laterally defining a build chamber, (B) a build box including a build plate, (C) a powder dispenser, (D) a beam system for fusing layers of powder, (E) a peripheral plate disposed between the build plate and the plurality of walls and having an upper surface, (F) a gas inlet that ejects a gas flow stream that passes over the build plate and the peripheral plate, (G) a gas outlet that receives the gas flow stream, (H) a plurality of projecting structures mounted to and extending above the upper surface of the peripheral plate, and (I) a gas handling system coupled to the gas inlet and gas outlet. The plurality of projecting structures shape the flow field of the gas flow stream to provide a more uniform velocity of gas flow velocities above the build plane.

According to one aspect, the present disclosure provides a system for manufacturing transition structures including fiber threads embedded within a metal component. The system may include a supply of base sheet metal. The system may include a conveyor supported on a plurality of rollers and configured to move the base sheet metal in a production direction. The system may include a plurality of stages arranged in the production direction. Each stage may include a channel forming device configured to form a channel in the base sheet metal, a fiber inserting device configured to insert a portion of a fiber material into the channel, and one or more ultrasonic welders configured to consolidate a layer of metal foil over the fiber. The disclosure includes methods of using the system to produce transition structures and reinforced components.

According to one aspect, the present disclosure provides a system for manufacturing transition structures including fiber threads embedded within a metal component. The system may include a supply of base sheet metal. The system may include a conveyor supported on a plurality of rollers and configured to move the base sheet metal in a production direction. The system may include a plurality of stages arranged in the production direction. Each stage may include a channel forming device configured to form a channel in the base sheet metal, a fiber inserting device configured to insert a portion of a fiber material into the channel, and one or more ultrasonic welders configured to consolidate a layer of metal foil over the fiber. The disclosure includes methods of using the system to produce transition structures and reinforced components.

An additive manufacturing system for producing a three-dimensional article includes a print engine, a post-fabrication powder removal apparatus, a transport mechanism, and a controller. The post fabrication removal apparatus includes a rotary frame defining an internal receptacle cavity, a plurality of clamps coupled to a corresponding plurality of actuators, a clamping plate coupled to a lift apparatus, and an agitation device mounted to the clamping plate. The controller is configured to perform the following steps: (1) Operate the transport mechanism to transport the build box to the internal receptacle cavity. (2) Operate the plurality of actuators to engage the build box with the plurality of clamps to secure the build box to the rotary frame. (3) Operate the rotary frame to rotate the build box until unfused powder begins to exit the build box. (4) Operate the agitation device to facilitate pouring of the unfused powder from the build box.

An additive manufacturing device (AMD) for manufacturing objects through deposition of superposed layers of material in a granulate or powder form, the AMD comprising: a hydraulic cylinder; a mold for sealable attachment to the hydraulic cylinder; a material deposition station having an outlet for depositing the material in the mold layer-by-layer; a heating element; and a compressor. Between the deposition of one or more layers of material in the mold, the mold and the hydraulic cylinder are sealably attached to form a pressure container, the compressor injects gas in the container to increase a pressure within the pressure container and the heating element provides heat within the pressure container to further increase the pressure and to perform sintering or high-temperature synthesis of the material while submitting the material to the pressure.

A system (1) for additive manufacturing of three-dimensional objects, comprising one or more working stations (21), which are provided for performing at least one working process in the additive manufacturing of three-dimensional objects, at least one freely positionable mobile storage unit (2) comprising a rack-like storage device (4) comprising at least one storage room (5) provided for storing at least one powder module (6), especially for the purpose of conveying the powder module (6) between different working stations (21) of the system (1), and at least one driverless, freely movable mobile conveying unit (3) comprising a receiving device (12) provided for receiving at least one mobile storage unit (2) for the purpose of conveying the storage unit (2) between different working stations (21) of the system (1).

A deployable manufacturing center (DMC) system includes a foundry module containing a metallurgical system configured to convert a raw material into an alloy powder, and an additive manufacturing (AM) module containing an additive manufacturing system configured to form the alloy powder into metal parts. The deployable manufacturing center (DMC) system can also include a machining module containing a machining system configured to machine the metal parts into machined metal parts, and a quality conformance (QC) module containing an inspection and evaluation system configured to inspect and evaluate the metal parts. A process for manufacturing metal parts includes the steps of providing the deployable manufacturing center (DMC) system; deploying the (DMC) system to a desired location; forming an alloy powder from a raw material using the deployable foundry module; and then forming the metal parts from the alloy powder using the additive manufacturing (AM) module.

A method of manufacturing a door hinge, which can improve productivity by applying both metal injection molding and additive manufacturing is disclosed. The method includes: preparing a first mixture of a first metal powder and a first binder, and a second mixture of a second metal powder and a second binder; molding the first mixture into a first body including a first connection member having a first pinhole; molding the first mixture into a second body including a second connection member having a second pinhole to communicate with the first pinhole; arranging the first body and the second body to align the first pinhole and the second pinhole along an axis to form a cavity; forming a pin member with the second mixture in the cavity by adding up droplets of the second mixture in the cavity; and sintering the first body, the second body, and the pin member.