A methodology integrating multiscale 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. A bone implant with a graded cellular microstructure is also provided.

Foamable semifinished product (1) in the form of granules produced from the metal alloy and the foam agent is inserted into the cavity of the closable mould (2) and the liquid (3) with the density that is higher than the apparent (or bulk) density of the resulting foam is led to it. The liquid has a temperature which is higher than the temperature of the melting of the metal alloy; the transfer of the heat to the particles of the foamable semifinished product (1) takes place; it subsequently expands, whereby it is supported by the liquid (3). During the expansion at least part of the liquid (3) is pushed by the expansion itself out of the mould (2) through the opening. The liquid (3) allows the regulation of the pressure of the environment of the foam agent, too, which helps to set exactly the moment of expansion. The metal melt can be advantageously used as liquid (3). The melt can partially remain in the mould (2) so the hybrid structure of the component is created. The new method makes the foaming significantly quicker, it secures the homogeneity of the metal foam, simplifies the moulds and diminishes the energy demands for the whole process.

A method for producing a piston may include forming a piston blank in a first forming tool such that the piston blank surrounds a ring carrier configured to receive a piston ring via positive engagement after producing the ring carrier by a sintering process. The piston blank, at least in a circumferential region disposed at a piston head, may be composed of a light metal alloy suitable for forging. The method may also include removing the piston blank from the first forming tool and placing the piston blank in a second forming tool, and inserting a holding-down tool into the second forming tool to hold the ring carrier down. The method may further include pressing a final forming punch into the second forming tool to deform the piston blank and form a piston.

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 method comprising depositing a part from layers of model material including sinterable metal particles and a first binder, the part surrounding a hole, depositing a first support structure from layers of the model material within the hole, depositing a first release layer of a release material above the first support structure and within the hole, the release material including a dispersed ceramic powder and a second binder, depositing a second release layer of a release material below the first support structure and within the hole, and forming a multipiece assembly of the part, the first and second release layers, and the first support structure, wherein, during sintering, the part and first support structure are configured to densify as a whole at a uniform rate, the release material is configured to reduce to a loose ceramic powder, and the first support structure is configured to prevent distortion of the hole.

A method comprising forming a shrinking platform of layers of a composite, the composite including a metal particulate filler in a first matrix, forming a shrinking support of layers of the composite upon the shrinking platform, forming a first release layer of a release material upon the shrinking support, the release material including a ceramic particulate and a second matrix, and forming a part of the composite upon the shrinking support to form a portable assembly from the combined shrinking platform, shrinking support, release layer and part, wherein substantially horizontal portions of the part are vertically supported by the shrinking platform, wherein the first release layer is configured, after sintering, to separate the part from the shrinking support and to allow the part to be readily removed from the shrinking support, and wherein the shrinking support is configured to prevent the part from distorting during sintering.

A method comprising depositing, in layers, a shrinking platform formed from a composite including metal particles embedded in a first matrix, depositing shrinking supports of the composite upon the shrinking platform, forming a separation clearance dividing at least one shrinking support into fragments, depositing, from the composite, a part upon the shrinking platform and shrinking supports, depositing a separation material intervening between the part and the shrinking supports, the separation material including a ceramic powder and a second matrix, and forming, from the shrinking platform, shrinking supports, separation material, and part, a portable platform assembly in a green state, wherein the shrinking support is configured to prevent the portable platform assembly from distorting from gravitational force during sintering of the metal particles of the assembly in a brown state, and wherein the ceramic powder of the separation material is configured to separate the shrinking support from the part following sintering.

According to one aspect, embodiments herein provide a method comprising forming a shrinking platform of model material above a build plate, the model material including sinterable metal particles and a first binder, forming a support structure of the model material extending up from the shrinking platform, forming a first portion of the part from successive layers of the model material above the support structure, forming a release layer intervening between a surface of the part and an opposing surface of the support structure or between a surface of the shrinking platform and an opposing surface of the build plate, the release layer including a dispersed ceramic powder and a second binder, and supporting the part, the release layer, and the support structure upon the shrinking platform to form a platform-integrating part assembly, the support structure being configured to prevent the first portion from distorting from gravitational force during sintering.

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.