Abstract:
Systems and methods for fabricating multi-functional articles comprised of additively formed gradient materials are provided. The fabrication of multi-functional articles using the additive deposition of gradient alloys represents a paradigm shift from the traditional way that metal alloys and metal/metal alloy parts are fabricated. Since a gradient alloy that transitions from one metal to a different metal cannot be fabricated through any conventional metallurgy techniques, the technique presents many applications. Moreover, the embodiments described identify a broad range of properties and applications.
Abstract:
Systems and methods in accordance with embodiments of the invention implement additive manufacturing techniques that employ different sets of deposition characteristics and/or material formation characteristics during the additive manufacture of an object so as to strategically build up the object. In many embodiments, material used to build up an object is deposited at different deposition rates during the additive manufacture of the object, and the object is thereby strategically built up. In one embodiment, a method of additively manufacturing an object includes: depositing material onto a surface at a first deposition rate so as to define a first region of the object to be additively manufactured; and depositing material onto a surface at a second deposition rate so as to define a second region of the object to be additively manufactured; where the second deposition rate is different from the first deposition rate.
Abstract:
Systems and methods in accordance with embodiments implement additive manufacturing processes that utilize multiple build heads. In one embodiment, an additive manufacturing apparatus includes: a plurality of build heads, each of which being adapted to cause the formation of a structure onto a surface; a substrate; and a translation system, where the translation system is associated with at least one of the plurality of build heads and the substrate, such that the spatial relationship between the plurality of build heads and the substrate can be controlled.
Abstract:
Systems and methods in accordance with embodiments of the invention fabricate objects including amorphous metals using techniques akin to additive manufacturing. In one embodiment, a method of fabricating an object that includes an amorphous metal includes: applying a first layer of molten metallic alloy to a surface; cooling the first layer of molten metallic alloy such that it solidifies and thereby forms a first layer including amorphous metal; subsequently applying at least one layer of molten metallic alloy onto a layer including amorphous metal; cooling each subsequently applied layer of molten metallic alloy such that it solidifies and thereby forms a layer including amorphous metal prior to the application of any adjacent layer of molten metallic alloy; where the aggregate of the solidified layers including amorphous metal forms a desired shape in the object to be fabricated; and removing at least the first layer including amorphous metal from the surface.
Abstract:
Systems and alloying methods for forming metals are described. Waste materials from various industrial processes and botched master alloy production heats result in numerous byproducts that can form constituent components for the formation of bulk alloys with higher value and more diverse applications. Reusing and upcycling industrial byproducts into material with specific structure and properties result in additional commercial and industrial applications and value.
Abstract:
Systems and methods for developing tough hypoeutectic amorphous metal-based materials for additive manufacturing, and methods of additive manufacturing using such materials are provided. The methods use 3D printing of discrete thin layers during the assembly of bulk parts from metallic glass alloys with compositions selected to improve toughness at the expense of glass forming ability. The metallic glass alloy used in manufacturing of a bulk part is selected to have minimal glass forming ability for the per layer cooling rate afforded by the manufacturing process, and may be specially composed for high toughness.
Abstract:
Harmonic drives (HDs) are used widely in robotics as a method for achieving high gear reductions and for driving force transmissions. The HD is made a three components: a wave generator, a flexspline, and a circular spline. Low-cost wave generators for metal strain wave gearing are provided. Wave generators are provided that incorporate commercially available bearings that form an ellipse either statically or through adjustment. Wave generators are optimized to maximum performance, including increasing the efficiency and the lifetime, while maximizing the running torque. The shape, size, number, type and location of the bearings can be changed so that the wave generator fails at a similar lifetime as a low cost flexspline. The shape of the wave generator may be adjusted to change the performance of the strain wave gear. The combination of low-cost flexsplines with low-cost wave generators reduces the cost of the strain wave gear.
Abstract:
A cutting tool with a cutting region and a connecting support region where the support region is designed to connect to an external motor assembly. The cutting tool is also has a porous region that is integrated within a portion of the tool such that as the tool cuts material the porous region can allow samples of the cut material to permeate into an internal chamber of the tool. Once in the internal chamber material samples can be analyzed in-situ for direct composition analysis.
Abstract:
Methods for the fabrication of metal strain wave gear flexsplines using a specialized metal additive manufacturing technique are provided. The method allows the entire flexspline to be metal printed, including all the components: the output surface with mating features, the thin wall of the cup, and the teeth integral to the flexspline. The flexspline may be used directly upon removal from the building tray.
Abstract:
Systems and methods in accordance with embodiments of the invention implement flexible members that include integrated tools made from metallic glass-based materials. In one embodiment, a structure includes: a flexible member characterized by an elongated geometry and an integrated tool disposed at one end of the elongated geometry; where the flexible member includes a metallic glass-based material.