The present invention relates to a gear wheel containing at least one sintered material having a porosity, the gear wheel having, in addition to the porosity, another noise-reducing means.

A system for additively manufacturing a composite structure is disclosed. The system may include a print head configured to discharge a matrix-coated reinforcement, and a support configured to move the print head in multiple dimensions during discharging of the matrix-coated reinforcement. The system may further include at least one cure enhancer located offboard the print head, and a controller in communication with the support and the at least one cure enhancer. The controller may be configured to selectively activate the at least one cure enhancer to expose the matrix-coated reinforcement to a cure energy during discharging of the matrix-coated reinforcement.

A head is disclosed for use with an additive manufacturing system. The head may include a housing, and a matrix reservoir disposed inside of the housing. The head may also include at least one roller located inside of the housing and configured to engage at least one of a ribbon and a sheet of reinforcement passing through the head. The head may further include a nozzle fluidly connected to the matrix reservoir, and a cure enhancer located outside of the housing and adjacent the nozzle.

Heat exchangers are manufactured by three-dimensional (3D) printers by printing subsequent layers of a material in a print direction. The heat exchangers include one or more tubes. The one or more tubes are configured to transport a fluid to be heated or cooled. Each of the one or more tubes defines a slope that is within a threshold angle of the print direction. The heat exchangers include a plurality of fins that are each configured to intersect with the one or more tubes while allowing fluid flow between the plurality of fins to heat or cool the fluid. Each fin of the plurality of fins defines a slope that is within a threshold angle of the print direction.

Heat exchangers are manufactured by three-dimensional (3D) printers by printing subsequent layers of a material in a print direction. The heat exchangers include one or more tubes. The one or more tubes are configured to transport a fluid to be heated or cooled. Each of the one or more tubes defines a slope that is within a threshold angle of the print direction. The heat exchangers include a plurality of fins that are each configured to intersect with the one or more tubes while allowing fluid flow between the plurality of fins to heat or cool the fluid. Each fin of the plurality of fins defines a slope that is within a threshold angle of the print direction.

A system for additively manufacturing a composite part is disclosed. The system may include a vat configured to hold a supply of resin, and a build surface disposed inside the vat. The system may also include a print head configured to discharge a matrix-coated continuous reinforcement onto the build surface, and an energy source configured to expose resin on a surface of the matrix-coated continuous reinforcement to a cure energy.

A methodology integrating muitiscale analysis and design optimization to design a novel bone replacement implant made of a functionally graded cellular material that meets fatigue requirements imposed by cyclic loadings. The pore microarchitecture, described by interconnectivity, porosity, pore size as well as pore topology, is optimally designed for tissue regeneration and mechanical strength. The method can contribute to the development of a new generation of bone replacement implants with a graded cellular microstructure.

According to one aspect, embodiments of the invention provide a method of 3D printing, comprising depositing a model material in successive layers to form a part, the model material being a metal composite including greater than 50% by volume metal powder and less than 50% by volume a first removable binder, depositing the model material in successive layers to form a support structure adjacent the part, depositing a sinterable separation material between a surface of the part and a surface of the support structure, the sinterable separation material formed from 10-40% by volume ceramic powder and greater than 50% by volume a second removable binder, debinding the first removable binder of the model material and the second removable binder of the sinterable separation material, and sintering the part, the support structure, and the sinterable separation material at a temperature profile that sinters the model material and the sinterable separation material.

An intake system assembly including an intake manifold including a housing defining an interior conduit in fluidic communication with an intake valve and a lattice structure extending from an outer surface of the housing. The lattice structure includes a plurality of intersecting walls and the lattice structure and the housing form a continuous piece of material.

To provide a metal filter having a small number of production steps and having high filtration performance, and a production method therefor. A mesh filter portion having a filtration function and a support portion that includes plural beam members supporting the mesh filter portion are seamlessly continuous to each other.