Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize a computer aided design (CAD) model of a part to develop a layer representation of the part. The method includes: determining a build layer thickness of an additive manufacturing apparatus; identifying a feature of the part within the model; determining that the feature is not aligned along the z-axis based on the build layer thickness; and moving the feature within the model along the z-axis by a feature offset such that the feature is aligned along the z-axis.

Abstract: A build assembly and a method of manufacturing the same are provided. The build assembly includes a first component, a second component, and a support structure coupling the two components together to fix their relative position. The support structure may be a “ghost” structure that is not connected with or does not contact the components, but is positioned such that the components are restrained to prevent distortion. The support structure may also be connected to the components and may define channels for removing additive powder from within or around the components.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize a computer aided design (CAD) model of a part to develop a layer representation of the part. The method includes: determining a build layer thickness of an additive manufacturing apparatus; identifying a feature of the part within the model; determining that the feature is not aligned along the z-axis based on the build layer thickness; and moving the feature within the model along the z-axis by a feature offset such that the feature is aligned along the z-axis.

Abstract: A disposable core die is provided. The disposable core die includes a first portion defining an inlet configured to receive a slurry therethrough, a second portion integrally formed downstream from the first portion and configured to receive the slurry from the first portion, and a third portion integrally formed downstream from the second portion. The second portion includes a plurality of hollow tubes that are substantially coaxially aligned and have a wall thickness within a range defined between about 0.1 mm and about 0.5 mm, and the third portion defines an outlet configured to discharge excess slurry from the second portion.

Abstract: A build assembly and a method of manufacturing the same are provided. The build assembly includes a first component, a second component, and a support structure coupling the two components together to fix their relative position. The support structure may be a “ghost” structure that is not connected with or does not contact the components, but is positioned such that the components are restrained to prevent distortion. The support structure may also be connected to the components and may define channels for removing additive powder from within or around the components.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize a computer aided design (CAD) model of a part to develop a layer representation of the part. The method includes: determining a build layer thickness of an additive manufacturing apparatus; identifying a feature of the part within the model; determining that the feature is not aligned along the z-axis based on the build layer thickness; and moving the feature within the model along the z-axis by a feature offset such that the feature is aligned along the z-axis.

Abstract: A disposable core die is provided. The disposable core die includes a first portion defining an inlet configured to receive a slurry therethrough, a second portion integrally formed downstream from the first portion and configured to receive the slurry from the first portion, and a third portion integrally formed downstream from the second portion. The second portion includes a plurality of hollow tubes that are substantially coaxially aligned and have a wall thickness within a range defined between about 0.1 mm and about 0.5 mm, and the third portion defines an outlet configured to discharge excess slurry from the second portion.

Abstract: A disposable core die includes a first portion defining an inlet configured to receive a slurry therethrough, a second portion integrally formed downstream from the first portion and configured to receive the slurry from the first portion, and a third portion integrally formed downstream from the second portion. The second portion includes a plurality of hollow tubes that are substantially coaxially aligned and have a wall thickness within a range defined between about 0.1 mm and about 0.5 mm, and the third portion defines an outlet configured to discharge excess slurry from the second portion.

Abstract: The present disclosure generally relates to methods for additive manufacturing (AM) that utilize a computer aided design (CAD) model of a part to develop a layer representation of the part. The method includes: determining a build layer thickness of an additive manufacturing apparatus; identifying a feature of the part within the model; determining that the feature is not aligned along the z-axis based on the build layer thickness; and moving the feature within the model along the z-axis by a feature offset such that the feature is aligned along the z-axis.