Abstract: Methods are disclosed for making articles (2) by three-dimensional printing. The methods include three-dimensional printing a build powder mixture which includes a first material powder and a second material powder to form a printed article and subsequently heating the printed article to a temperature at which a sufficient amount of the second material powder melts to enable it to infiltrate throughout the interstices between the first material powder particles so that the article (2) achieves a room temperature relative density of at least 85 percent of its theoretical density, the theoretical density being the density the article (2) would have if it contained no porosity. The first material powder has a melting temperature, melting temperature range, or dissociation temperature which is higher than the melting temperature or melting temperature range of the second material powder and the first material powder has no more than a limited amount of solubility in the second material powder.

Abstract: Apparatuses are disclosed for three-dimensionally printing reactive materials which utilize a powder spreading step followed by a binder-jet deposition step. Some such apparatuses include a binder jet three-dimensional printing device, a curing device, and a depowdering device contained within an environmental enclosure which provides an inert atmosphere sufficient to allow a reactive material to be used as a build material without fire or explosion hazards. Some such apparatuses include one or more conveying systems for moving a removable build box among the various devices. Environmental enclosures having unique designs and features are disclosed.

Abstract: Methods are disclosed of making metal casting molds and components thereof by the three-dimensional printing process in which an untreated sand is used as the build material and a polymer is used as a component of the binder that is printed onto the build material.

Abstract: Methods are presented for making sintered articles from water-atomized nickel-based superalloy powders. Three-dimensional binder jet printing is used to make a printed article from the powder. The printed article is liquid phase sintered without slumping at a temperature at which at least fifteen volume percent of the powder is liquid during sintering.

Abstract: Methods are disclosed for making articles (2) by three-dimensional printing. The methods include three-dimensional printing a build powder mixture which includes a first material powder and a second material powder to form a printed article and subsequently heating the printed article to a temperature at which a sufficient amount of the second material powder melts to enable it to infiltrate throughout the interstices between the first material powder particles so that the article (2) achieves a room temperature relative density of at least 85 percent of its theoretical density, the theoretical density being the density the article (2) would have if it contained no porosity. The first material powder has a melting temperature, melting temperature range, or dissociation temperature which is higher than the melting temperature or melting temperature range of the second material powder and the first material powder has no more than a limited amount of solubility in the second material powder.

Abstract: Methods are disclosed for making a hot isostatic pressing container for hot isostatic pressing a powder material to form an article comprising three-dimensionally printing the container from a build powder, the container having a cavity for receiving the powder material and an outer section having an outer surface, the cavity having a surface and being shaped and sized so that hot isostatic pressing the container with the powder material within the cavity results in the production of the article. Methods are also disclosed for making the hot isostatically pressed article using the container.

Abstract: Methods are disclosed of making metal casting molds and components thereof by the three-dimensional printing process in which an untreated sand is used as the build material and a polymer is used as a component of the binder that is printed onto the build material.

Abstract: Apparatuses are disclosed for three-dimensionally printing reactive materials which utilize a powder spreading step followed by a binder-jet deposition step. Some such apparatuses include a binder jet three-dimensional printing device, a curing device, and a depowdering device contained within an environmental enclosure which provides an inert atmosphere sufficient to allow a reactive material to be used as a build material without fire or explosion hazards. Some such apparatuses include one or more conveying systems for moving a removable build box among the various devices. Environmental enclosures having unique designs and features are disclosed.