A fabrication method involving the use of additive material fabrication methods to create a shell representative of a desired part, the additive material shell being used in one or more molding fabrication methods in which a second material is provided into a cavity of the shell.

Steels, in particular hot work steels having high toughness even for high thickness, including steels having long durability combined with mechanical, tribological and thermal properties for highly demanding applications, and steels which can achieve a very good environmental resistance and resistance to certain aggressive media combined with other relevant properties, are described. These steels may also be obtained at low cost. A method for the manufacture of steels having high thickness and manufacturing methods to shape the materials of the invention through several steps, including an additive manufacturing step to manufacture at least a part of an intermediate mold, a mold or a model, a Cold Isostatic Pressing (CIP) step, the elimination of the mold and densification among other steps, are also described.

Steels, in particular hot work steels having high toughness even for high thickness, including steels having long durability combined with mechanical, tribological and thermal properties for highly demanding applications, and steels which can achieve a very good environmental resistance and resistance to certain aggressive media combined with other relevant properties, are described. These steels may also be obtained at low cost. A method for the manufacture of steels having high thickness and manufacturing methods to shape the materials of the invention through several steps, including an additive manufacturing step to manufacture at least a part of an intermediate mold, a mold or a model, a Cold Isostatic Pressing (CIP) step, the elimination of the mold and densification among other steps, are also described.

A capsule 2 for HIPing comprises a rigid, self-supporting additive manufactured (AM) component 3 which is welded to inner and outer cylindrical liners 4, 6 through which cooling channel tubes 8, 10 extend. A solid end plate 11 is welded to ends of the liners 4, 6 and tubes 8, 10 extend through the end plate 11 and open to the outside. A fill tube 12 communicates with an annular void 14 defined between liners 4, 6 which is filled with powder 16. In use, the capsule 2 is subjected to Hot Isostatic Pressing (HIP). Thereafter, the inner and outer liners 4, 6 are removed to define a valve seat assembly comprising the AM component 3, tubes 8, 10, HIPed powder 16 and end plate 11.

The present disclosure provides for a method of making a part using powder metallurgy and material extrusion. The method includes forming a mold of a first material using material extrusion. The method includes depositing a second material within the mold. The second material is deposited as a powder. The method includes compacting the second material within the mold, and heating the mold and the second material within the mold. During the heating, the mold is separated from the material by melting, evaporating, or burning of the first material, and the second material is sintered. Also provided for are parts made by the method and a system for making such parts. The system includes a material extrusion head and a powder deposition head. Each head is articulable along three axes.

In one aspect, an additive manufacturing system is provided. The additive manufacturing system includes a build platform, a first plurality of particles positioned on the build platform, and a particle containment system positioned on the build platform. The particle containment system includes a particle containment wall. The particle containment wall at least partially surrounds the first plurality of particles and includes a second plurality of particles consolidated together. The particle containment wall includes a top end spaced apart from the build platform, an inner face positioned against the first plurality of particles and extending between the build platform and the top end, and an outer face that faces a substantially particle-free region, the outer face positioned opposite the inner face and extending between the build platform and the top end.

A cutter for use with a drill bit includes: a substrate for mounting in a pocket of the drill bit and made from a cermet material; a cutting table made from a polycrystalline superhard material and mounted to the substrate; and a shield disposed in an outer recess of the substrate adjacent to the cutting table, mounted to the substrate, extending from the cutting table along a partial length of the substrate, and made from a composite material comprising the polycrystalline superhard material and a ceramic.

A cutter for use with a drill bit includes: a substrate for mounting in a pocket of the drill bit and made from a cermet material; a cutting table made from a polycrystalline superhard material and mounted to the substrate; and a shield disposed in an outer recess of the substrate adjacent to the cutting table, mounted to the substrate, extending from the cutting table along a partial length of the substrate, and made from a composite material comprising the polycrystalline superhard material and a ceramic.

A method of forming tooling for fabricating a part made from a metal powder is described herein. The method includes forming a first sheet and second sheet. The first sheet includes a first protrusion defining a first cavity and a first flange extending about the first protrusion. The second sheet includes a second flange. Additionally, the method includes arranging the first sheet and the second sheet to abut together the first flange of the first sheet and the second flange of the second sheet and to define an enclosure. The enclosure includes a void defined between the first cavity of the first sheet and the second sheet. The void has a shape of the part. The method further includes welding together the first flange of the first sheet and the second flange of the second sheet along a portion of the first flange spaced away from the first protrusion.

A method and apparatus for removing a canister 12 from a component 18 by forming an opening 30 in the canister wall thickness 14, 16 and introducing a pressurised fluid into the opening 14, 16 causing hydrostatic pressure build up between an internal canister surface 14 and the component 18, leading to the removal of the canister 12. This method and apparatus obviates the need to expend significant machining or chemical processing to remove the canister 12.