A method of forming a functionally designed cemented tungsten carbide can include forming a particulate matrix mixture including a primary particulate tungsten carbide and a primary particulate metal binder. A particulate enhancement mixture can be formed having a secondary particulate tungsten carbide, a secondary particulate metal binder, and a particulate grain growth inhibitor, where the enhancement mixture has a finer particle size than the matrix mixture. The particulate matrix mixture can be assembled with the particulate enhancement mixture to form a structured composite where the matrix mixture forms a continuous phase and the enhancement mixture forms at least one of a dispersed granular phase and a surface layer adjacent the continuous phase to form the structured composite. This structured composite can be sintered to form the functionally designed cemented tungsten carbide having a differential grain size with the enhancement phase having a smaller grain size than the matrix phase.

A method of forming a functionally designed cemented tungsten carbide can include forming a particulate matrix mixture including a primary particulate tungsten carbide and a primary particulate metal binder. A particulate enhancement mixture can be formed having a secondary particulate tungsten carbide, a secondary particulate metal binder, and a particulate grain growth inhibitor, where the enhancement mixture has a finer particle size than the matrix mixture. The particulate matrix mixture can be assembled with the particulate enhancement mixture to form a structured composite where the matrix mixture forms a continuous phase and the enhancement mixture forms at least one of a dispersed granular phase and a surface layer adjacent the continuous phase to form the structured composite. This structured composite can be sintered to form the functionally designed cemented tungsten carbide having a differential grain size with the enhancement phase having a smaller grain size than the matrix phase.

A method for controlling grain growth in articles of manufacture produced using nano-particle jetting additive manufacturing processes includes the steps of; providing or obtaining nanoparticles of a bulk material, providing or obtaining nanoparticles of a dopant material different from the bulk material, supplying the bulk material and the dopant material to a nano-particle jetting apparatus, and using the nano-particle jetting apparatus, building-up the article of manufacture in a layer-by-layer manner. Each layer includes a mixture of the bulk material particles and the dopant material particles. Furthermore, the method includes sintering the article of manufacture. During sintering, the presence of the dopant material mixed with the bulk material moderates the grain growth of the bulk material.

A method for controlling grain growth in articles of manufacture produced using nano-particle jetting additive manufacturing processes includes the steps of; providing or obtaining nanoparticles of a bulk material, providing or obtaining nanoparticles of a dopant material different from the bulk material, supplying the bulk material and the dopant material to a nano-particle jetting apparatus, and using the nano-particle jetting apparatus, building-up the article of manufacture in a layer-by-layer manner. Each layer includes a mixture of the bulk material particles and the dopant material particles. Furthermore, the method includes sintering the article of manufacture. During sintering, the presence of the dopant material mixed with the bulk material moderates the grain growth of the bulk material.

Methods for manufacturing a beryllium-based article object comprising beryllium by depositing layers of beryllium. An element is added to the beryllium that dissolved to form a secondary phase to limit columnar grain. Grain refinement allows the beryllium article to have beneficial properties in terms of strength and durability.

Methods for manufacturing an object comprising beryllium by depositing layers of beryllium and metal inoculants are disclosed. Grain refinement allows the beryllium article to have beneficial properties in terms of strength and durability.

A 3D printing system may print a desired 3D object. A fusible powder may fuse when subjected to a fusing condition. A deposition system may deposit portions of the fusible powder on a substrate. A fusing system may apply the fusing condition to the deposited fusible powder. Inhibitor material may not fuse when subjected to the fusing condition. An insertion system may insert a portion of the inhibitor material between portions of the deposited fusible powder after having been deposited by the deposition system, but before being fused by the fusing system, so as to form a boundary that defines at least a portion of a surface of the desired 3D object.

Some variations provide a functionalized composite material comprising: a thermoplastic polymer binder matrix disposed in a distinct volume; a plurality of discrete metal or metal alloy particles dispersed in the thermoplastic polymer matrix; and a plurality of discrete particulates assembled on surfaces of the discrete metal or metal alloy particles, wherein the discrete particulates are in contact with the thermoplastic polymer binder matrix, wherein the discrete particulates are smaller than the discrete metal or metal alloy particles in at least one dimension, and wherein the discrete particulates are compositionally different than the discrete metal or metal alloy particles. The discrete particulates may be selected and/or configured to function as a grain refiner, a sintering aid, and/or a strengthening phase, within the functionalized composite material.

A method to additively manufacture multi-material parts including directly depositing a part material through a print head having a number of degrees of freedom to a growing part, directly depositing a binder through the print head or a different print head having a number of degrees of freedom to the growing part simultaneously with or temporally shifted from the depositing of the part material. A method to additively manufacture multi-material parts including directly depositing to a growing part, a part material that is itself coated with a binder, through a print head having a number of degrees of freedom.

A method to additively manufacture multi-material parts including directly depositing a part material through a print head having a number of degrees of freedom to a growing part, directly depositing a binder through the print head or a different print head having a number of degrees of freedom to the growing part simultaneously with or temporally shifted from the depositing of the part material. A method to additively manufacture multi-material parts including directly depositing to a growing part, a part material that is itself coated with a binder, through a print head having a number of degrees of freedom.