A rotor shroud for a rotary machine in a cabin air compressor includes a disk portion centered on a central axis of the rotor shroud, a frustoconical portion extending from the disk portion, a flared portion extending from the frustoconical portion, and a variable lattice structure in an interior of the rotor shroud. The variable lattice structure includes a first region of the rotor shroud having a first lattice structure and a second region of the rotor shroud having a second lattice structure. The second lattice structure of the second region is denser than the first lattice structure of the first region. The second region is a deflection region, a stress region, or an energy containment region of the rotor shroud.

A rotor shroud for a rotary machine in a cabin air compressor includes a disk portion centered on a central axis of the rotor shroud, a frustoconical portion extending from the disk portion, a flared portion extending from the frustoconical portion, and a variable lattice structure in an interior of the rotor shroud. The variable lattice structure includes a first region of the rotor shroud having a first lattice structure and a second region of the rotor shroud having a second lattice structure. The second lattice structure of the second region is denser than the first lattice structure of the first region. The second region is a deflection region, a stress region, or an energy containment region of the rotor shroud.

A rotor for a rotary machine in includes a hub centered on a central axis and having a disk portion and a shaft portion, a blade extending outward from the hub, and a variable lattice structure in an interior of the rotor. The variable lattice structure includes a first region of the rotor having a first lattice structure and a second region of the rotor having a second lattice structure. The second lattice structure of the second region is denser than the first lattice structure of the first region. The second region is a deflection region or a stress region of the rotor.

A rotor for a rotary machine in includes a hub centered on a central axis and having a disk portion and a shaft portion, a blade extending outward from the hub, and a variable lattice structure in an interior of the rotor. The variable lattice structure includes a first region of the rotor having a first lattice structure and a second region of the rotor having a second lattice structure. The second lattice structure of the second region is denser than the first lattice structure of the first region. The second region is a deflection region or a stress region of the rotor.

A hybrid three-layer system is presented. The hybrid three-layer system includes a two-layer composite system and an additively manufactured third layer comprising a lattice structure. The composite layer system includes a metallic substrate, a structured surface, and a thermal protection system. The structured surface may be additively manufactured onto the metallic substrate and includes structured surface features formed to project above the metallic substrate. Each of the structured surface features are separated from adjacent structured surface features by grooves. The thermal protection coating may be thermally sprayed onto the structured surface and is bonded to each of the structured surface features. The lattice structure is in contact with a surface of the metallic substrate of the composite layer system.

Methods and apparatuses for using a structure as a sensor are disclosed. An apparatus in accordance with an aspect of the present disclosure comprises an additively-manufactured component comprising a channel, a sensor including an connection point, wherein the sensor is arranged in the channel, and an adhesive arranged in the channel, the adhesive coupling the additively-manufactured component to the sensor, such that the connection point is accessible external to the adhesive, the sensor being configured to provide a signal at the connection point, wherein the signal provides information of an applied force on the additively-manufactured component.

A computer-generated component file for fabricating an orthopedic implant is prepared. First and second select sections of an initial implant model of a computer-aided design model are set to first and second model porous sections. A remaining section of the initial implant model is left. All regions defining the first and the second select sections are spaced not more than a preset distance from a patient-specific bone model of the computer-aided design model as measured uniformly. The first and the second model porous sections are merged with a remaining section of the initial implant model to form at least a portion of a final implant model. The final implant model is stored in a component file configured to be accessed by a computer-aided manufacturing machine for use in fabricating the orthopedic implant. At least a portion of the orthopedic implant corresponds to the final implant model.

A three-dimensional structure is formed when layers of a material are deposited onto a substrate and scanned with a high energy beam to at least partially melt each layer of the material. Upon scanning the layers at predetermined locations a tube device having a first tube and a second tube intersected with the first tube is formed.

A three-dimensional structure is formed when layers of a material are deposited onto a substrate and scanned with a high energy beam to at least partially melt each layer of the material. Upon scanning the layers at predetermined locations a tube device having a first tube and a second tube intersected with the first tube is formed.

Systems and methods for generating graded lattice structures that can be used as infill for additively manufactured articles. Tailored sectioning and field-based smoothing are modified polygon, e.g., circle, packing algorithms that adjust the size of the circles based on physical field data to adapt the infill generation process to a field expected to be experienced by the article. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from tailored sectioning, field-based smoothing, and force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.