Provided herein are manufacturing methods, e.g., comprising: (1a) forming a layer, including: depositing a starting material including a mixture of a metal and a sacrificial material; and applying a laser beam to the deposited starting material to consolidate the deposited starting material and form the layer; (1b) optionally repeating (1a) one or more times; and (1c) at least partially removing the sacrificial material to form a porous metal part.

A medical implant which comprises a porous lattice is fabricated with additive manufacturing techniques such as direct metal laser sintering. A CAD model of the porous lattice is created by defining a trimming volume and merging some lattice elements with adjacent solid substrate.

Apparatus and associated methods relate to using an additive (material deposition) process to incrementally form a closed-cell lattice structure formed as a unitary body in the shape of a marine hull cavity, the unit cells of the closed-cell lattice structure are substantially hollow. In an illustrative example, a method may include (a) forming a closed-cell lattice structure through additive manufacture, the hull cavity material may be bonded to an upper manufactured liner and a lower manufactured liner through lamination or mechanical connection. Unit cells of the closed-cell lattice structure may include hollow voids filled with gases. Providing the additive manufactured closed-cell lattice structure with a unitary body and hollow voids to trap gases may further advantageously promote the buoyancy and reduce the degeneration of a marine hull.

A medical implant which comprises a porous lattice is fabricated with additive manufacturing techniques such as direct metal laser sintering. A CAD model of the porous lattice is created by defining a trimming volume and merging some lattice elements with adjacent solid substrate.

Alloy materials and three-dimensional (3-D) printed alloys are disclosed. An alloy in accordance with an aspect of the present disclosure comprises aluminum, magnesium, and silicon wherein a composition of the alloy comprises from at least 5 percent (%) by weight to 20% by weight of silicon and from at least 7% by weight to 10% by weight of magnesium.

A linking member between a first and a second structural member of a fuselage of an aircraft allowing improved dissipation of stresses. The linking member has a first part made of a solid structure and at least one second part made of a lattice structure. The first part made of the solid structure is configured to dissipate static stresses and to withstand fatigue up to a predetermined maximum stress and fatigue threshold. This configuration allows improved dissipation of the stresses exerted on the linking member.

Methods, systems, and apparatus, including medium-encoded computer program products, for volumetric kernel representation of three dimensional models include: modeling a three dimensional object using a volumetric representation including fields that determine volumetric properties, each of the fields being parameterized by an input and output tensor structure, and at least one of the fields mapping tensor output of a first of the fields to tensor input of a second of the fields to provide a unified framework for geometry manipulation and composition that encompasses both discrete and continuous representations of materials in the three dimensional space; evaluating the fields including using coverage values that determine compositing behavior to generate output data corresponding to the volumetric properties; and providing the output data for the three dimensional object having physical characteristics that vary from point to point within a volume of the three dimensional object in accordance with the volumetric properties.

A method for forming a multi-material mechanical functional member in additive manufacturing. The method includes the following steps: S1: dividing an object to be formed into a plurality of portions, analyzing and measuring mechanical properties of each portion, and constructing a unit cell library; S2: forming a lattice structure by using a unit cell structure in the unit cell library to obtain the lattice structure corresponding to each portion; S3: selecting a raw material of the lattice structure, measuring and comparing mechanical properties of each lattice structure with the mechanical properties of each portion of the object to be formed, where when the mechanical properties of each portion are satisfied, the lattice structure is the required lattice structure, otherwise, step S2 is repeated; and S4: forming a three-dimensional model by a method of additive manufacturing to accordingly obtain the required object to be formed.

A method for forming a multi-material mechanical functional member in additive manufacturing. The method includes the following steps: S1: dividing an object to be formed into a plurality of portions, analyzing and measuring mechanical properties of each portion, and constructing a unit cell library; S2: forming a lattice structure by using a unit cell structure in the unit cell library to obtain the lattice structure corresponding to each portion; S3: selecting a raw material of the lattice structure, measuring and comparing mechanical properties of each lattice structure with the mechanical properties of each portion of the object to be formed, where when the mechanical properties of each portion are satisfied, the lattice structure is the required lattice structure, otherwise, step S2 is repeated; and S4: forming a three-dimensional model by a method of additive manufacturing to accordingly obtain the required object to be formed.

A porous heat exchanger including a single piece core extending axially is provided. The core defines a first air inlet and a first air outlet for a first fluid, a second air inlet and a second air outlet for a second fluid. The first/second fluid flows into the core from the first/second air inlet through a first/second fluid channel and flows out of the core through the first/second air outlet. The core includes solid material sheets and porous material sheets disposed alternately with the solid material sheets so each porous material sheet has an adjacent solid material sheet on each side defining one of the first fluid channel for a flow of the first fluid or the second fluid channel for a flow of the second fluid. Heat transfer occurs between the first fluid in the first fluid channel and the second fluid in the second fluid channel.