Methods for forming a hole in a coated component are provided. The method may include forming a sacrificial layer over a ceramic barrier coating of a substrate, drilling a hole into the coated component such that any spatter formed during drilling deposits onto the sacrificial layer, and removing the sacrificial layer along with the spatter deposited thereon. The sacrificial layer may include a rare earth oxide (e.g., rare earth oxide particles). Intermediate ceramic matrix composite (CMC) component are also provided. The intermediate CMC may include a CMC body, an environmental barrier coating on the bond coating, and a sacrificial layer on the environmental barrier coating, with the sacrificial layer including particles of a rare earth oxide dispersed in a polymeric matrix.

Apparatus related to conformal coating implemented with surface mount devices. In some embodiments, a radio-frequency (RF) module includes a packaging substrate configured to receive a plurality of components. The RF also includes a surface mount device (SMD) mounted on the packaging substrate, the SMD including a metal layer that faces upward when mounted. The RF module further includes an overmold formed over the packaging substrate, the overmold dimensioned to cover the SMD. The RF module further includes an opening defined by the overmold at a region over the SMD, the opening having a depth sufficient to expose at least a portion of the metal layer. The RF module further includes a conformal conductive layer formed over the overmold, the conformal conductive layer configured to fill at least a portion of the opening to provide an electrical path between the conformal conductive layer and the metal layer of the SMD.

A light emitting method includes passing a laser beam through at least one offset assembly and a focusing assembly in sequence, and actuating, by a control-manipulating mechanism, the offset assembly to cause the laser beam to be offset, so that the laser beam can quickly produce a controllable opening of any shape in a drilling process.

A laser hole drilling system. The system includes a laser source that generates a laser beam along an optical axis, a cylindrical lens along the optical axis downstream of the laser source, and a spherical lens downstream of the cylindrical lens, the spherical lens offset from the optical axis to provide an anamorphic optical train to generate an asymmetric teardrop shaped energy distribution at a focal plane.

A laser hole drilling system includes a laser source that generates a laser beam along an optical axis; a spherical lens along the optical axis downstream of the laser source; and a control system in communication with the spherical lens and the laser source, the control system operable to locate the spherical lens with respect to the laser source to produce a light distribution in polar coordinates of a real portion of the Fourier Transform to generate an asymmetric teardrop shaped energy distribution at a focal plane.

The present invention presents a method of fabrication for a physiological sensor with electronic, electrochemical, and chemical components. The fabrication method comprises steps for manufacturing an apparatus comprising at least one electrochemical sensor, a microcontroller, and a transceiver. The fabrication process includes the steps of substrate fabrication, circuit fabrication, pick and place, reflow soldering, electrode fabrication, membrane fabrication, sealing and curing, layer bonding, and dressing. The physiological sensor is operable to analyze biological fluids such as sweat.

A system includes a laser-line imaging subsystem to measure a feature. The laser-line imaging subsystem includes a laser to project a laser-line, and a digital video camera mounted at an angle with respect to an axis of said laser to obtain an optical image of the laser-line. A control subsystem is operable to compute three-dimensional coordinate points via triangulation of an intersection between the laser-line and the optical image of the laser-line, the three-dimensional coordinate points data used by the control subsystem to calculate predictive airflow through the workpiece with respect to the volume of the machined holes.

A method for disposing blocking material within an interior of a component for blocking a beam of radiation from a laser during a laser drilling operation, the method including forming one of a multiple of apertures formed via a first process and forming the remainder of the multiple of apertures formed via a laser drilling process. A component for a gas turbine engine includes a surface with at least one of a multiple of apertures formed via a first process, the at least one of the multiple of apertures formed via the first process in communication with a cavity, a remainder of the multiple of apertures formed via a laser drilling process, the remainder of the multiple of apertures in communication with the cavity.

A system of producing metal cored solder structures on a substrate includes: a decal, a carrier, and receiving elements. The decal includes one or more apertures each of which is tapered from a top surface to a bottom surface thereof. The carrier is positioned beneath the bottom of the decal and includes cavities in a top surface. The cavities are located in alignment with the apertures of the decal. The decal is positioned on the carrier having the decal bottom surface in contact with the carrier top surface to form feature cavities defined by the decal apertures and the carrier cavities. The feature cavities are shaped to receive one or more metal elements and are configured for receiving molten solder cooled in the cavities. The decal is separable from the carrier to partially expose metal core solder contacts. The receiving elements receive the metal core solder contacts thereon.

A method for producing a cavity in a blade platform of a blade, in particular of a turbine blade, as part of a blade-platform cooling system, wherein the method has the steps of: producing a first bore from a first platform lateral face in the direction of an opposite second platform lateral face, with a first opening in the first platform lateral face being created, and expanding the first bore in a fan-like manner by an electrical discharge machining method, in particular using a wire- or bar-form electrode, such that the first opening, created in the first step, of the first bore represents the starting point of the fan-like expansion. A blade is produced in particular with such a method.