Ut-battelle, Inc.

University of Tennessee Research Foundation

Haier US Appliance Solutions, Inc.

North Carolina State University

Virginia Tech Intellectual Properties, Inc.

Carpenter Technology Corporation

Eck Industries, Inc.

Amelia M Elliott

Corson L Cramer

David C Anderson

Derek H Siddel

Anibal J Ramirez-Cuesta

Matthew B Stone

Michael Goodman Schroeder

Mariappan Parans Paranthaman

Orlando Rios

James William Klett

David J Weiss

Hunter B Henderson

Zachary C Sims

Tomonori Saito

Christopher Bryant Williams

Richard A Lowden

Ayyoub Mehdizadeh Momen

James O Kiggans, Jr

Craig A Bridges

Edgar Lara-Curzio

Amit Shyam

Michael S Kesler

Kashif Nawaz

Chins Chinnasamy

Peeyush Nandwana

Brian A Fricke

Jacob W McMurray

Dustin Blake Gilmer

Kinga A Unocic

Alex E Pawlowski

Zachary C Cordero

Nicholas Alexander Meisel

Lu Han

Bianca Haberl

Garrett E Granroth

Richard R Lowden

Prashant K Jain

Matthew J Sandlin

Vivek M Rao

Sarita Sepulveda

M A Muktadir

Kelsey L Hedrick

Sameer Hamoush

Makayla S Edwards

Ryan K Duncan

Sun Yi

Alex G Hessler

Derek A Splitter

David Lee McCarthy

Collimators and other components for use in neutron scattering experiments or to provide neutron shielding in nuclear reactors or accelerator based neutron sources are produced by additive manufacturing from neutron absorbing material, such as boron carbide (BC) or isotopically enriched boron carbide (B).

Method for producing neutron collimators using additive manufacturing

Systems and methods for additive manufacturing of objects are disclosed. The system includes an object builder subsystem configured to additively manufacture an object in a powder bed, an object extraction subsystem configured to extract the object from the powder bed, and a depowdering subsystem configured to remove powder from the object while the object is gripped by the gripper assembly. The object extraction subsystem includes a gripper assembly comprising two or more gripper members that each include a perforated mesh structure.

Systems and methods for automated depowdering and transfer of additively manufactured objects

A bonded soft magnet object comprising bonded soft magnetic particles of an iron-containing alloy having a soft magnet characteristic, wherein the bonded soft magnetic particles have a particle size of at least 200 nm and up to 100 microns. Also described herein is a method for producing the bonded soft magnet by indirect additive manufacturing (IAM), such as by: (i) producing a soft magnet preform by bonding soft magnetic particles with an organic binder, wherein the magnetic particles have an iron-containing alloy composition with a soft magnet characteristic, and wherein the particles of the soft magnet material have a particle size of at least 200 nm and up to 100 microns; (ii) subjecting the preform to an elevated temperature sufficient to remove the organic binder to produce a binder-free preform; and (iii) sintering the binder-free preform at a further elevated temperature to produce the bonded soft magnet.

Indirect additive manufacturing process for fabricating bonded soft magnets

A method for additively manufacturing a microstructure from a caloric material includes providing a geometry of the microstructure to a processor of an additive manufacturing device, the geometry defining a plurality of microfeatures of the microstructure. The method also includes generating, via the processor, a three-dimensional (3D) model representative of the geometry of the microstructure, wherein one or more of the plurality of microfeatures are represented in the 3D model by a non-arcuate profile. Further, the method includes printing, via the additive manufacturing device, the microstructure from the caloric material according to the 3D model. As such, the non-arcuate profile reduces a file size of the 3D model as compared to an arcuate profile.

Systems and methods for additively manufacturing caloric microstructures

A method for additive manufacturing of a composite object containing a bonded network of boron carbide particles and aluminum occupying spaces between boron carbide particles, the method comprising: (i) producing a porous preform constructed of boron carbide by an additive manufacturing process in which particles of boron carbide are bonded together; and (ii) infiltrating molten aluminum, at a temperature of 1000-1400° C., into pores of said porous preform to produce said composite object constructed of boron carbide particles within an aluminum matrix, wherein the boron carbide is present in the composite object in an amount of 30-70 wt. %. The resulting composite material is also herein described.

Additive manufacturing process for producing aluminum-boron carbide metal matrix composites

A method for fabricating heat exchangers using additive manufacturing technologies. Additive manufacturing enables the manufacture of heat exchangers with complex geometries and/or with internal and external integral surface features. Additive manufacture also facilitates the manufacture of heat exchangers with regional variations, such as changes in size, shape and surface features. In one embodiment, the present invention provides a heat exchanger with a helicoidal shape that provides axial elastic compliance. In one embodiment, the internal channel of the heat exchanger varies along its length. The internal channel may have a cross-sectional area that increases progressively from one end to the other. In one embodiment, the external shape of the tubular structure may be non-circular to optimize heat transfer with an external heat transfer fluid. In one embodiment, the present invention provides a heat pipe with an internal wicking structure formed as an integral part of the additive manufacturing process.

Compliant heat exchangers, heat pipes and methods for making same

A reactive matrix infiltration process is described herein, which includes contacting a surface of a preform comprising reinforcement material particles with a molten infiltrant comprising a matrix material, the matrix material comprising an Al&#x2014;Ce alloy, whereby the infiltrant at least partially fills spaces between the reinforcement material particles by capillary action and reacts with the reinforcement material particles to form a composite material form, the composite material comprising the matrix material, at least one intermetallic phase, and, optionally, reinforcement material particles. A composite material form also is described, which includes a plurality of reinforcement material particles comprising a metal alloy or a ceramic, a matrix material at least partially filling spaces between the reinforcement material particles; and at least one intermetallic phase surrounding at least some of the reinforcement material particles. The reinforcement material particles and intermetallic phase together may form a gradient core-shell structure.

Reactive matrix infiltration of powder preforms

Collimators and other components for use in neutron scattering experiments or to provide neutron shielding in nuclear reactors or accelerator based neutron sources are produced by additive manufacturing from multiple different types of material, such as boron carbide (BC), steel, isotopically enriched boron carbide (BC), and blends thereof.

Additive manufacturing of composite neutron absorbing components

A washout tooling for a composite layup is provided. The washout tooling comprises a casting mold having an exterior surface. The casting mold comprises a particulate material and a water-soluble binder. The casting mold is adapted to break down in the presence of an aqueous solution. The washout tooling further comprises a water-soluble coating layer overlying the exterior surface. The water-soluble coating layer is adapted to break down in the presence of an aqueous solution. The washout tooling further comprises a curable composite layer overlying the water-soluble coating layer. The water-soluble coating layer minimizes contact between the particulate material and the curable composite layer.

Water soluble barrier coatings for washout tooling for a composite layup

Method for producing collimators and other components from neutron absorbing materials using additive manufacturing

A method for indirect additive manufacturing of an object constructed of boron carbide, silicon carbide, and free silicon, comprising: (i) producing a porous preform constructed of boron carbide and silicon carbide by an indirect ceramic additive manufacturing (ICAM) process in which particles of a powder mixture become bonded together with an organic binder, wherein the powder mixture comprises: a) boron carbide particles, and b) silicon carbide particles, wherein at least 80 vol % of the silicon carbide particles are larger than the boron carbide particles; and wherein the boron carbide and silicon carbide particles are each included in an amount of 40-60 wt. % of the powder mixture, provided that the foregoing amounts sum to at least 95 wt. %; (ii) subjecting the porous preform to a temperature of 500-900&#xb0; C. to volatilize the organic binder; and (iii) infiltrating molten silicon into pores of the porous preform to produce the object.

Indirect additive manufacturing process for producing SiC&#x2014;B4C&#x2014;Si composites

A method for preparing metal/metal interpenetrating phase composites is provided. The method includes forming a preform using additive manufacturing. The preform defines a materially continuous three-dimensional open-cell mesh structure. The preform includes a first metal having a melting point. The method further includes pre-heating the preform to a first temperature less than the melting point of the first metal. The method includes infiltrating the preform with a second metal in liquid form. The second metal has a melting point lower than the melting point of the first metal. The method also includes allowing the second metal to cool and form a solid matrix. The solid matrix defines a continuous material network.

Additive manufactured interpenetrating phase composite

An apparatus and device for building an article by additive manufacturing or 3-D printing. The method includes feeding a supply of particulate slurry to and through a nozzle, such as including an integrated pump, to form a plurality of beads and layers of the slurry on a deposition surface, and ultimately forming a desirable article from the layers of deposited material. The liquid phase of the slurry is desirably removed by heat, and the deposited layers can be sintered or otherwise fused as needed.

Apparatus and method for three-dimensional metal printing

A build platform and methods of fabricating an article with such a platform in an extrusion-type additive manufacturing machine are provided. A platform bodyincludes featuresthat extend outward from the body. The featuresdefine protrusive areasand recessive areasthat cooperate to mechanically engage the extruded material that forms the initial layersof an article when the article is being fabricated by a nozzleof the additive manufacturing machine

Method for producing mechanical engagement between a build platform and additive manufacturing prints

Build platform that provides mechanical engagement with additive manufacturing prints

Growing community of inventors

Cleveland, TN, United States of America

Amelia M Elliott