A method of electroforming can be used to prepare a heat exchanger by electroforming the heat exchanger on a mandrel having a smooth and conductive surface. The mandrel is in the shape of at least part of the heat exchanger, and is removed from the electroformed heat exchanger.

A gas turbine engine guide vane heat exchanger has guide vane heat exchanger including electroformed fluid channels in electroformed heat exchanger tubes or a heat exchanger core disposed within airfoil. Non-flammable heat conducting liquid or non-metallic foam may fill space between tubes or core and airfoil. Fluid circuit may include channels within electroformed heat exchanger tubes or the heat exchanger core and extend from inlet manifold to outlet manifold for directing fluid or oil through channels and include fluid or oil supply inlet connected to inlet manifold for receiving the fluid or oil flowed into inlet manifold and a fluid or oil supply outlet connected to fluid or oil supply outlet for discharging fluid or oil flowed out of fluid or oil outlet manifold. Heat exchanger tubes or heat exchanger core, inlet manifold, outlet manifold, supply inlet and supply outlet may be integrally and monolithically electroformed together.

A gas turbine engine guide vane heat exchanger has guide vane heat exchanger including electroformed fluid channels in electroformed heat exchanger tubes or a heat exchanger core disposed within airfoil. Non-flammable heat conducting liquid or non-metallic foam may fill space between tubes or core and airfoil. Fluid circuit may include channels within electroformed heat exchanger tubes or the heat exchanger core and extend from inlet manifold to outlet manifold for directing fluid or oil through channels and include fluid or oil supply inlet connected to inlet manifold for receiving the fluid or oil flowed into inlet manifold and a fluid or oil supply outlet connected to fluid or oil supply outlet for discharging fluid or oil flowed out of fluid or oil outlet manifold. Heat exchanger tubes or heat exchanger core, inlet manifold, outlet manifold, supply inlet and supply outlet may be integrally and monolithically electroformed together.

A strengthened component includes a sacrificial material mold of the component having an outer surface, an insert having an inner surface and an outer surface opposite and spaced from the inner surface such that the strengthening insert inner surface abuts the mold outer surface, and a metallic layer deposited over the exposed mold outer surface and the exposed strengthening insert outer surface, where the sacrificial material mold is removed from the strengthened component.

A strengthened component includes a sacrificial material mold of the component having an outer surface, an insert having an inner surface and an outer surface opposite and spaced from the inner surface such that the strengthening insert inner surface abuts the mold outer surface, and a metallic layer deposited over the exposed mold outer surface and the exposed strengthening insert outer surface, where the sacrificial material mold is removed from the strengthened component.

A deflectable, flexible device includes an elongate body, a convoluted tip portion at a distal end of the elongate body, and a lumen to receive one or more wires. The convoluted tip portion includes an electroformed pleated region which is formed by electrodepositing a metal on a mandrel having a pleated region. The convoluted tip portion may be hermetically sealed to permit repeated sterilization. The electroformed pleated region may include one or more fluid emission orifices. The convoluted tip portion extends or bends in response to fluid pressure manipulation, contact with tissue, manipulation with an internal spring or wire, or by a user pushing, pulling, or twisting the catheter directly or via an introducer sheath or the like. The convoluted tip portion may further include an RF ablation element or other energy-driven technique to create continuous linear lesions or a sensing element.

A deflectable, flexible device includes an elongate body, a convoluted tip portion at a distal end of the elongate body, and a lumen to receive one or more wires. The convoluted tip portion includes an electroformed pleated region which is formed by electrodepositing a metal on a mandrel having a pleated region. The convoluted tip portion may be hermetically sealed to permit repeated sterilization. The electroformed pleated region may include one or more fluid emission orifices. The convoluted tip portion extends or bends in response to fluid pressure manipulation, contact with tissue, manipulation with an internal spring or wire, or by a user pushing, pulling, or twisting the catheter directly or via an introducer sheath or the like. The convoluted tip portion may further include an RF ablation element or other energy-driven technique to create continuous linear lesions or a sensing element.

A manufacturing process for making aircraft engine parts utilizes reusable reconfigurable smart memory polymer mandrel tooling, low temperature metal deposition, and composite part lay-up with resin coated conformable braided carbon fiber sleeves, to fabricate both metal internal engine parts and non-metal external parts for turbine engines.

A manufacturing process for making aircraft engine parts utilizes reusable reconfigurable smart memory polymer mandrel tooling, low temperature metal deposition, and composite part lay-up with resin coated conformable braided carbon fiber sleeves, to fabricate both metal internal engine parts and non-metal external parts for turbine engines.

A component can be formed having an integral monolithic body. The integral monolithic body can be formed utilizing electroforming processes such as electrodeposition of metal alloys. The electroformed monolithic body can be formed utilizing multiple anodes powered by multiple power sources. The monolithic body can have differing local material properties determined during formation of the component.