A system and method for forming electrical devices via additive manufacturing processes that utilize starting materials that are in a solid state at least prior to, as well as after, the formation of the electrical device. A first solid starting material can be configured to form one or more insulator layers of the electrical device, while another solid starting material can be applied to form one or more electrically conductive layers. The starting materials canbe applied layer-by-layer during formation of the electrical device such that the electrically conductive layers can become automatically embedded within the insulating layers, and vice versa. The additive manufacturing process(es) utilized to form the electrically conductive layers from solid starting materials can be different than the additive manufacturing process(es) utilized to form the insulator layers.

A method of additive forming of a 3D object by layering solid base blocks (3) comprises the following steps: a. arranging at least one guiding element (2) oriented in the direction of forming of the 3D object; b. depositing a first layer comprising at least one solid base block (3) in the horizon of the first layer; c. depositing at least one further layer comprising at least one solid base block (3) at a horizon spatially spaced from the horizon of the first layer in the direction of forming the 3D object;
while at least one base block (3) of the at least one layer is arranged in the region of the at least one guiding element (2) and is arranged with at least one cooperating means (4), cooperating with the said at least one guiding element (2).

3D object can also contain various solid base blocks (3). It is advantageous if the first layer is arranged on the base plate (1). It is advantageous if at least one base block (3) is arranged with a fastening means (5), for example an adhesive. It is advantageous if, after step c), the base plate (1) and/or the at least one guiding elements (2) are removed. The 3D object can be strengthened by a thermal process.

A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations. Methods for generation of different periodic and non-periodic structures and joints using the process-controlled solid-state additive manufacturing system are also disclosed.

A process control system and a method for process control of a solid-state additive manufacturing system capable of performing various additive processes, such as joining, additive manufacturing, coating, repair and others, are disclosed. The process control system is capable of simultaneous measuring, monitoring and controlling multiple process variables, viz. material temperature, actuator down force, tool force (or torque), tool position, tool angular and transverse velocity, spindle torque (angular velocity), filler flow rate, filler composition, track width, inert gas flow rate and others. A feeding system for continuous supply of filler material to the solid-state additive manufacturing system is also disclosed. The filler material can be in a form of a powder, granules, briquettes, beads, flakes, wires, rods, films, scrap pieces, sheets, blocks or their combinations. Methods for generation of different periodic and non-periodic structures and joints using the process-controlled solid-state additive manufacturing system are also disclosed.

A process for manufacturing a composite material of 3-D shape, includes a stack of layers of resin and fibre, incorporating at least one metal layer, the process comprising the following steps, a standard unit pattern having been determined for the metal layer: i/computing periodically organized patterns on the 3-D shape, which is non-developable; then projecting, onto a plane, the patterns, thus defining a planar organization of second patterns; ii/partially polymerizing, flat, first layers, comprising a metal top layer, of the flat composite stack, so as to make it etchable, but to keep it still deformable; iii/electrochemically etching the organization of second patterns that was defined in step i into the metal top layer of the flat composite stack resulting from step iv/carrying out polymerization of the etched composite stack after the stack has been placed in a mould having the desired 3-D shape.

A process for manufacturing a composite material of 3-D shape, includes a stack of layers of resin and fibre, incorporating at least one metal layer, the process comprising the following steps, a standard unit pattern having been determined for the metal layer: i/computing periodically organized patterns on the 3-D shape, which is non-developable; then projecting, onto a plane, the patterns, thus defining a planar organization of second patterns; ii/partially polymerizing, flat, first layers, comprising a metal top layer, of the flat composite stack, so as to make it etchable, but to keep it still deformable; iii/electrochemically etching the organization of second patterns that was defined in step i into the metal top layer of the flat composite stack resulting from step iv/carrying out polymerization of the etched composite stack after the stack has been placed in a mould having the desired 3-D shape.

A method for the additive manufacturing of an object and a system for manufacturing an object. The method includes depositing a second foil sheet onto the first foil sheet, wherein the first foil sheet and the second foil sheet each comprise a structural layer, forming a layer stack comprising the first foil sheet and the second foil sheet, the layer stack comprising an object section and at least one support section configured to enclose the object section in the layer stack, and applying at least one of heat or pressure to opposite sides of the layer stack with a first plate and a second plate, wherein applying the at least one of heat or pressure increases he temperature of the layer stack to a temperature lower than the melting temperature of the structural layer, and the at least one of at or pressure bonds the first foil sheet to the second foil sheet in the layer stack, the first plate and the second plate are in contact with the at least one support section, and the at least one support section is configured to conduct the at least one of heat or pressure through the layer stack to the object section.

A method for the additive manufacturing of an object and a system for manufacturing an object. The method includes depositing a second foil sheet onto the first foil sheet, wherein the first foil sheet and the second foil sheet each comprise a structural layer, forming a layer stack comprising the first foil sheet and the second foil sheet, the layer stack comprising an object section and at least one support section configured to enclose the object section in the layer stack, and applying at least one of heat or pressure to opposite sides of the layer stack with a first plate and a second plate, wherein applying the at least one of heat or pressure increases he temperature of the layer stack to a temperature lower than the melting temperature of the structural layer, and the at least one of at or pressure bonds the first foil sheet to the second foil sheet in the layer stack, the first plate and the second plate are in contact with the at least one support section, and the at least one support section is configured to conduct the at least one of heat or pressure through the layer stack to the object section.

A 3-D printer includes build and support material development stations that electrostatically transfer build material and support material to an ITB. The ITB transfers a layer of build and support material to a platen each time the platen contacts one of the layers on the ITB, to successively form a freestanding stack of the layers on the platen. A sensor is positioned to generate a topographic measurement of the layer on the platen, and an aerosol applicator is positioned to propel build and support material on to the layer on the platen. The aerosol applicator controls the build and support material being propelled, based on the topographic measurement from the sensor through a feedback loop, to adjust the amount and location of the build material and the support material propelled on to the layer, and thereby control the flatness of surface topology of the layers in the freestanding stack on the platen.

A method for manufacturing a blade made of composite material for a turbine engine, in particular of an aircraft, the steps of injecting a resin in order to impregnate a fibrous preform woven in three dimensions and polymerizing the resin so as to form the blade that includes an airfoil, one longitudinal end of which is connected to a platform. The platform includes pressure and suction portions connected to the airfoil by a fillet, wherein a separation is formed in the fibrous preform between the pressure and suction portions. The method further includes reinforcing a leading edge of the airfoil; and reinforcing the fillets by integration of a metal reinforcement on at least one part of the pressure and suction portions of the platform and in the separation.