Abstract: The present disclosure relates to an additive manufacturing system. In one embodiment the system makes use of a reservoir for holding a granular material feedstock. A nozzle is in communication with the reservoir for releasing the granular material feedstock in a controlled fashion from the reservoir to form at least one layer of a part. An excitation source is included for applying a signal which induces a controlled release of the granular material feedstock from the nozzle as needed, to pattern the granular material feedstock as necessary to form a layer of the part.

Abstract: A separator made of ion conductive ink is produced by additive manufacturing. A micro-battery is produced with the separator made of ion conductive ink located between the battery's anode and cathode. The separator functions to keep the anode and cathode apart and to facilitate the transport of ions to produce an operative micro-battery.

Abstract: The present disclosure relates to an apparatus for additively manufacturing a product in a layer-by-layer sequence, wherein the product is formed using powder particles deposited on an interface layer of a substrate. A laser generates first and second beam components, where the second beam component has a substantially higher power level and a substantially shorter duration than the first beam component. A mask is used to create a 2D optical pattern in which only select portions of the first and second beam components are allowed to irradiate the powdered particles. The first beam component heats the powder particles at least to substantially a melting point, at which point the particles begin to experience surface tension forces relative to the interface layer.

Abstract: Disclosed here is a method for making an architected three-dimensional aerogel, comprising providing a photoresin comprising a solvent, a photoinitiator, a crosslinkable polymer precursor, and a precursor for graphene, metal oxide or metal chalcogenide; curing the photoresin using projection microstereolithography layer-by-layer to produce a wet gel having a pre-designed three dimensional structure; drying the wet gel to produce a dry gel; and pyrolyzing the dry gel to produce an architected three-dimensional aerogel. Also disclosure is a photoresin for projection microstereolithography, comprising a solvent, a photoinitiator, a crosslinkable polymer precursor, and graphene oxide.

Abstract: A system for additive manufacturing uses a pulsed laser beam with one or more low flux components on the order of kW/cm2, and one or more high flux components on the order of MW/cm2 during the duration of the pulse. The pulsed laser beam is directed onto the powder particles on the substrate thereby melting the powder particles and melting the substrate at the interface layer between the powder and the substrate such that the powder particles bond to the substrate. This is accomplished by using low power (and low cost) lasers to do the majority of the energy transfer, and using high power (and higher cost) lasers to complete the melting process, overcoming the kinetics of powder agglomeration through surface tension forces by partially melting the powder-substrate interface layer before surface tension can take effect on the molten powder particles.

Abstract: Disclosed here is a method for making an architected three-dimensional aerogel, comprising providing a photoresin comprising a solvent, a photoinitiator, a crosslinkable polymer precursor, and a precursor for graphene, metal oxide or metal chalcogenide; curing the photoresin using projection microstereolithography layer-by-layer to produce a wet gel having a pre-designed three dimensional structure; drying the wet gel to produce a dry gel; and pyrolyzing the dry gel to produce an architected three-dimensional aerogel. Also disclosure is a photoresin for projection microstereolithography, comprising a solvent, a photoinitiator, a crosslinkable polymer precursor, and graphene oxide.

Abstract: Apparatus, systems, and methods that ultrasonically agitate a semisolid metal slurry to prevent dendrite formation that can lead to clogging of a nozzle during direct metal writing.

Abstract: An additive manufacturing system for producing metal parts from pure metal or eutectic alloys. The system includes an additive manufacturing print head, a print head heater system, an agitation system, a nozzle in the additive manufacturing print head, a reservoir for melting the metal, and a long heated tube for conditioning the alloy for extrusion in the semi-solid state through a nozzle.

Abstract: A system for separating components of a fluid containing at least a first component and a second component includes a device having an inlet for introducing the fluid into the device, a first outlet for directing the first component of the fluid from the device, and a second outlet for directing the second component of the fluid from the device. A material that has a gradient in properties is located in the device between the inlet and the first and second outlets. The material has a first portion with an affinity for the first fluid component and a second portion with an affinity for the second fluid component. The first portion is positioned with relation to the first outlet such that the first component is directed from said device through the first outlet. The second portion is positioned with relation to the second outlet such that the second component is directed from the device through the second outlet.

Abstract: Method and apparatus for separating a target substance from a fluid or mixture. Capsules having a coating and stripping solvents encapsulated in the capsules are provided. The coating is permeable to the target substance. The capsules having a coating and stripping solvents encapsulated in the capsules are exposed to the fluid or mixture. The target substance migrates through the coating and is taken up by the stripping solvents. The target substance is separated from the fluid or mixture by driving off the target substance from the capsules.

Abstract: A separator made of ion conductive ink is produced by additive manufacturing. A micro-battery is produced with the separator made of ion conductive ink located between the battery's anode and cathode. The separator functions to keep the anode and cathode apart and to facilitate the transport of ions to produce an operative micro-battery.

Abstract: Method and apparatus for separating a target substance from a fluid or mixture. Capsules having a coating and stripping solvents encapsulated in the capsules are provided. The coating is permeable to the target substance. The capsules having a coating and stripping solvents encapsulated in the capsules are exposed to the fluid or mixture. The target substance migrates through the coating and is taken up by the stripping solvents. The target substance is separated from the fluid or mixture by driving off the target substance from the capsules.

Abstract: Disclosed here is a method for making an architected three-dimensional aerogel, comprising providing a photoresin comprising a solvent, a photoinitiator, a crosslinkable polymer precursor, and a precursor for graphene, metal oxide or metal chalcogenide; curing the photoresin using projection microstereolithography layer-by-layer to produce a wet gel having a pre-designed three dimensional structure; drying the wet gel to produce a dry gel; and pyrolyzing the dry gel to produce an architected three-dimensional aerogel. Also disclosure is a photoresin for projection microstereolithography, comprising a solvent, a photoinitiator, a crosslinkable polymer precursor, and graphene oxide.

Abstract: A separator made of ion conductive ink is produced by additive manufacturing. A micro-battery is produced with the separator made of ion conductive ink located between the battery's anode and cathode. The separator functions to keep the anode and cathode apart and to facilitate the transport of ions to produce an operative micro-battery.

Abstract: Providing high energy materials that can be placed in previously created fractures and activating them in place to extend or change an existing fracture system. Also detecting the location of fractures or permeable pathways and a means to assess the extent and efficiency of proppant emplacement.

Abstract: A capsule for carrying a proppant for emplaced in a formation containing formation fluid by a hydraulic fracture operation using a fracturing fluid. The capsule includes a capsule body. The capsule body includes a proppant. There is a surface layer on the capsule body that is permeable to the formation fluid or the fracturing fluid or is permeable to both the formation fluid and the fracturing fluid. The proppant material is dry cement that interacts with the formation fluid or the fracturing fluid or both the formation fluid and the fracturing fluid that migrate through the surface layer and is taken up by the dry cement causing the dry cement to harden.

Abstract: A multi-beam volumetric resin curing system and method for whole-volume additive manufacturing of an object includes a bath containing a photosensitive resin, a light source for producing a light beam, and a spatial light modulator which produces a phase- or intensity-modulated light beam by impressing a phase profile or intensity profile of an image onto a light beam received from the light source. The system and method also include projection optics which then produces multiple sub-image beams from the modulated light beam which are projected to intersect each other in the photosensitive resin to cure select volumetric regions of the resin in a whole-volume three-dimensional pattern representing the object.

Abstract: A capsule for carrying a proppant for emplaced in a formation containing formation fluid by a hydraulic fracture operation using a fracturing fluid. The capsule includes a capsule body. The capsule body includes a proppant. There is a surface layer on the capsule body that is permeable to the formation fluid or the fracturing fluid or is permeable to both the formation fluid and the fracturing fluid. The proppant material is dry cement that interacts with the formation fluid or the fracturing fluid or both the formation fluid and the fracturing fluid that migrate through the surface layer and is taken up by the dry cement causing the dry cement to harden.

Abstract: Encapsulated solids are made by first encapsulating precursor materials in a polymer shell. The precursors are some combination of solids, liquids, gases, and/or gels. The precursors are then transformed into solids by emplacement of the capsule in an environment where gas or fluid transport into or out of the polymer shell causes transformation into solids.

Abstract: Systems provide cooling of an optic such as an optically addressed light valve such that the valve is sensitive to temperature and pressure variations and is thus temperature and pressure controlled. In the case of an optic such as an optically addressed light valve, the fluid pressure outside the valve is low enough that it does not compress the liquid crystal gap of the valve. The cooling fluid is transparent to the high powered wavelength of light used during operation such as in an additive manufacturing process.