A testing apparatus for use with a laser processing system that includes a laser for generating a non-stationary laser beam and a work plane positioned at a working distance relative to the non-stationary laser beam, wherein the testing apparatus includes a support tube; a protective window mounted in the support tube for protecting components mounted within the support tube; a reimaging lens mounted in the support tube for enlarging the non-stationary laser beam for characterization thereof; a pin-hole defining structure mounted in the support tube for receiving laser light generated by the laser beam, wherein the pin-hole is located at a predetermined distance from the reimaging lens; a fiber optic cable disposed within the pin-hole defining structure that has a proximal end at which the laser light is received through the pin-hole and a distal end to which the laser light is delivered; and a photodetector located at the distal end of the fiber optic cable that converts the laser light delivered to the photodetector into electrical voltage output signals based on intensity of the laser light received through the pin-hole.

Method of manufacturing a wellbore downhole tool, including providing a pre-polymer resin and processing the pre-polymer resin. Processing the pre-polymer resin includes applying directed energy from a directed energy source such that the pre-polymer resin is at least partially polymerized to form a polymer seal of the wellbore downhole tool, the polymer seal having one of more mechanical properties that differ along one or more dimensions of the polymer seal. A downhole tool for use in a wellbore, the downhole tool including a polymer seal. The polymer seal is a continuous single monolithic piece, includes polymer structures having a polymer chain including same types of monomers that are bonded together, and the polymer structures are altered along one or more dimensions of the polymer seal and one of more mechanical properties of the polymer seal differ along a same corresponding one of the or more dimensions of the polymer seal.

Method of manufacturing a wellbore downhole tool, including providing a pre-polymer resin and processing the pre-polymer resin. Processing the pre-polymer resin includes applying directed energy from a directed energy source such that the pre-polymer resin is at least partially polymerized to form a polymer seal of the wellbore downhole tool, the polymer seal having one of more mechanical properties that differ along one or more dimensions of the polymer seal. A downhole tool for use in a wellbore, the downhole tool including a polymer seal. The polymer seal is a continuous single monolithic piece, includes polymer structures having a polymer chain including same types of monomers that are bonded together, and the polymer structures are altered along one or more dimensions of the polymer seal and one of more mechanical properties of the polymer seal differ along a same corresponding one of the or more dimensions of the polymer seal.

A method of forming an object from a material includes directing a first beam of light toward a first target location of the material to define a first portion of the object. The method also includes, after directing the first beam of light toward the first target location, determining an optical correction to be applied by an optical system. The optical correction is based on an atmospheric change in an atmospheric distortion region proximate the first target location due, at least in part, to interaction of the first beam of light and the material. The method further includes directing a second beam of light toward a second target location of the material to define a second portion of the object. The second beam of light is directed through at least a portion of the atmospheric distortion region while the optical correction is applied.

A method of forming an object from a material includes directing a first beam of light toward a first target location of the material to define a first portion of the object. The method also includes, after directing the first beam of light toward the first target location, determining an optical correction to be applied by an optical system. The optical correction is based on an atmospheric change in an atmospheric distortion region proximate the first target location due, at least in part, to interaction of the first beam of light and the material. The method further includes directing a second beam of light toward a second target location of the material to define a second portion of the object. The second beam of light is directed through at least a portion of the atmospheric distortion region while the optical correction is applied.

A Pulsed Thermography (PT) system and method is provided utilizing a long duration pulse in combination with a radiant heat shield as a non-destructive testing method for quantitatively measuring defect depths within a 3D printed part and for characterizing layer-by-layer surface defects in the 3D printed part.

A Pulsed Thermography (PT) system and method is provided utilizing a long duration pulse in combination with a radiant heat shield as a non-destructive testing method for quantitatively measuring defect depths within a 3D printed part and for characterizing layer-by-layer surface defects in the 3D printed part.

Herein disclosed is a method of manufacturing comprises depositing a composition on a substrate slice by slice to form an object; heating in situ the object using electromagnetic radiation (EMR); wherein said composition comprises a first material and a second material, wherein the second material has a higher absorption of the radiation than the first material. In an embodiment, the EMR has a wavelength ranging from 10 to 1500 nm and the EMR has a minimum energy density of 0.1 Joule/cm.sup.2. In an embodiment, the EMR comprises UV light, near ultraviolet light, near infrared light, infrared light, visible light, laser, electron beam. In an embodiment, said object comprises a catalyst, a catalyst support, a catalyst composite, an anode, a cathode, an electrolyte, an electrode, an interconnect, a seal, a fuel cell, an electrochemical gas producer, an electrolyser, an electrochemical compressor, a reactor, a heat exchanger, a vessel, or combinations thereof.

Herein disclosed is a method of manufacturing comprises depositing a composition on a substrate slice by slice to form an object; heating in situ the object using electromagnetic radiation (EMR); wherein said composition comprises a first material and a second material, wherein the second material has a higher absorption of the radiation than the first material. In an embodiment, the EMR has a wavelength ranging from 10 to 1500 nm and the EMR has a minimum energy density of 0.1 Joule/cm.sup.2. In an embodiment, the EMR comprises UV light, near ultraviolet light, near infrared light, infrared light, visible light, laser, electron beam. In an embodiment, said object comprises a catalyst, a catalyst support, a catalyst composite, an anode, a cathode, an electrolyte, an electrode, an interconnect, a seal, a fuel cell, an electrochemical gas producer, an electrolyser, an electrochemical compressor, a reactor, a heat exchanger, a vessel, or combinations thereof.

A three-dimensional shaping apparatus includes a stage, a first material supply unit that supplies a first material, a second material supply unit that supplies a second material having a thermal expansion coefficient larger than a thermal expansion coefficient of the first material, a laser irradiation unit, and a control unit that controls the laser irradiation unit by selecting a first laser irradiation mode and a second laser irradiation mode in which heat diffusion to an adjacent region is smaller than in the first laser irradiation mode, wherein when a first material region and a second material region are adjacently disposed in the shaped layer for one layer, and the second material region is irradiated with a laser from the laser irradiation unit, the second laser irradiation mode is selected for a region adjacent to the first material region.