Abstract: Additive manufacturing processes, systems and three-dimensional articles include the formation of voxels and/or portions of three-dimensional articles with different properties relative to other voxels and/or portions. The processes generally include changing one or more laser beam parameters including power level, exposure time, hatch spacing, point distance, velocity, and energy density during the formation of selected voxels and/or portions of the three-dimensional articles. Also disclosed are processes that include an additive manufacturing process that provides localized secondary heat treatment of certain voxels and/or regions at a temperature below the melting point of the three-dimensional article but high enough to effect a localized property change.

Abstract: A process for autonomous mechanical property testing of specimens on a build plate includes fabricating a plurality of the specimens on a build plate, wherein each of the specimens comprises an upper portion and a lower portion integral to the build plate. Each of the upper portions of the specimens on the build plate are sequentially engaged with an end effector on a terminal end of a multi-linked robotic arm, wherein the end effector is configured to engage the upper portion and apply a uni- or multi-modal load, wherein intermediate the end effector and the multi-linked robotic arm comprises a multi-axis load cell for measuring an applied load. The process further includes autonomously calculating one or more mechanical properties from the applied load.

Abstract: A method for printing a semiconductor material includes depositing a molten metal onto a substrate in an enclosed chamber to form a trace having a maximum height of 15 micrometers and/or a maximum width of 25 micrometers to 10 millimeters and/or a thin film having a maximum height of 15 micrometers. The method further includes reacting the molten metal with a gas phase species in the enclosed chamber to form the semiconductor material. The depositing the molten metal includes depositing a metal composition including the molten metal and an etchant or depositing the etchant separate from the molten metal in the enclosed chamber.

Abstract: A rapid material development process for a powder bed fusion additive manufacturing (PBF AM) process generally utilizes a computational fluid dynamics (CFD) simulation to facilitate selection of a simulated parameter set, which can then be used in a design of experiments (DOE) to generate an orthogonal parameter space to predict an ideal parameter set. The orthogonal parameter space defined by the DOE can then be used to generate a multitude of reduced volume build samples using PBF AM with varying laser or electron beam parameters and/or feedstock chemistries. The reduced volume build samples are mechanically characterized using high throughput techniques and analyzed to provide an optimal parameter set for a 3D article or a validation sample, which provides an increased understanding of the parameters and their independent and confounding effects on defects and microstructure.

Abstract: Additive manufacturing processes, systems and three-dimensional articles include the formation of voxels and/or portions of three-dimensional articles with different properties relative to other voxels and/or portions. The processes generally include changing one or more laser beam parameters including power level, exposure time, hatch spacing, point distance, velocity, and energy density during the formation of selected voxels and/or portions of the three-dimensional articles. Also disclosed are processes that include an additive manufacturing process that provides localized secondary heat treatment of certain voxels and/or regions at a temperature below the melting point of the three-dimensional article but high enough to effect a localized property change.

Abstract: A method for printing a semiconductor material includes depositing a molten metal onto a substrate in an enclosed chamber to form a trace having a maximum height of 15 micrometers and/or a maximum width of 25 micrometers to 10 millimeters and/or a thin film having a maximum height of 15 micrometers. The method further includes reacting the molten metal with a gas phase species in the enclosed chamber to form the semiconductor material. The depositing the molten metal includes depositing a metal composition including the molten metal and an etchant or depositing the etchant separate from the molten metal in the enclosed chamber.

Abstract: A rapid material development process for a powder bed fusion additive manufacturing (PBF AM) process generally utilizes a computational fluid dynamics (CFD) simulation to facilitate selection of a simulated parameter set, which can then be used in a design of experiments (DOE) to generate an orthogonal parameter space to predict an ideal parameter set. The orthogonal parameter space defined by the DOE can then be used to generate a multitude of reduced volume build samples using PBF AM with varying laser or electron beam parameters and/or feedstock chemistries. The reduced volume build samples are mechanically characterized using high throughput techniques and analyzed to provide an optimal parameter set for a 3D article or a validation sample, which provides an increased understanding of the parameters and their independent and confounding effects on defects and microstructure.

Abstract: A process for estimating tensile properties associated with a metal additive manufactured component is disclosed. The process includes building ductile metal specimen samples layer-by-layer on a build plate by additive manufacturing, wherein each of the metal specimen samples includes at least one support member and a bridging member spanning a space defined by the at last one support member, wherein the bridging member includes an upper portion that is raised relative to top planar surfaces of the at least one support member, and a lower portion integrally bridging the space defined by the at least one support member and raised relative to the build plate. The process includes sequentially shear testing each of the plurality of specimen samples on the build plate by applying a load to the upper portion of the bridging member and measuring load, displacement and/or local strain values.

Abstract: An additive manufacturing apparatus includes a laser and a detection system. The laser emits a laser beam to heat a powder bed to form a melt pool, and the melt pool emits light proportional to a temperature of the melt pool. The detection system includes a spectral disperser and one of a) two or more on-axis sensors or b) a line scanner. The two or more on-axis sensors or the line scanner are/is located along an axis of the emitted light, the detection system receives the emitted light from the melt pool, and an intensity of the emitted light detected by the a) two or more on-axis sensors or the b) line scanner is compared with a blackbody spectral map at a particular wavelength of the emitted light to determine a temperature of the melt pool.

Abstract: Regenerable carbon dioxide scrubbers are provided. The regenerable carbon dioxide scrubbers include at least a first housing compartment including an inlet, an outlet, and an interior region. A sorbent material is located within the interior region of the first housing compartment, in which the sorbent material (a) attracts and/or retains carbon dioxide from an air supply passing through the sorbent material at an operating temperature below about 100° C., and (b) releases carbon dioxide at a regenerating temperature above about 150° C. Rebreathers including the regenerable carbon dioxide scrubbers and methods of scrubbing carbon dioxide from a user's exhaled air are also provided.

Abstract: A method for monitoring and analyzing an additive manufacturing process includes heating a melt zone to fuse an additive media with an active layer to build a part being manufactured based on a part design model, capturing raw melt data of the melt zone, and generating an active layer dataset that is spatially defined. The method may also include analyzing the active layer dataset with respect to a plurality of defect signatures within a defect signature library. The defect signature library may be predefined based on a machine learning processing of historical sensor datasets with corresponding ground truth datasets. The method may also include detecting a defect in the part based on the analysis of the active layer dataset with respect to a plurality of defect signatures, simultaneously with the energy source acting upon the active layer of the part for manufacturing of the part.

Abstract: A system provided herein may be configured to evaluate helmet performance. The system may include an impact assembly that includes a stationary post operably coupled to one or more stationary load cells and a plurality of modular headforms. Each modular headform may include a first side and a second side configured to lock together around the impact assembly and receive a helmet. The modular headform may determine a position of the helmet relative to the one or more stationary load cells. Furthermore, the one or more stationary load cells may be configured to measure impact force at a position where one of the plurality of the modular headforms are operably coupled to the impact assembly. Additionally, each of the plurality of modular headforms correspond to a position in relation to the impact assembly to measure the impact force to the one or more load cells at a predefined number of impact locations on the helmet to evaluate the performance of the helmet.

Abstract: A rapid material development process for a powder bed fusion additive manufacturing (PBF AM) process generally utilizes a computational fluid dynamics (CFD) simulation to facilitate selection of a simulated parameter set, which can then be used in a design of experiments (DOE) to generate an orthogonal parameter space to predict an ideal parameter set. The orthogonal parameter space defined by the DOE can then be used to generate a multitude of reduced volume build samples using PBF AM with varying laser or electron beam parameters and/or feedstock chemistries. The reduced volume build samples are mechanically characterized using high throughput techniques and analyzed to provide an optimal parameter set for a 3D article or a validation sample, which provides an increased understanding of the parameters and their independent and confounding effects on defects and microstructure.

Abstract: A method for printing a semiconductor material includes depositing a molten metal onto a substrate in an enclosed chamber to form a trace having a maximum height of 15 micrometers and/or a maximum width of 25 micrometers to 10 millimeters and/or a thin film having a maximum height of 15 micrometers. The method further includes reacting the molten metal with a gas phase species in the enclosed chamber to form the semiconductor material. The depositing the molten metal includes depositing a metal composition including the molten metal and an etchant or depositing the etchant separate from the molten metal in the enclosed chamber.

Abstract: Functionalized metallic feedstock and three-dimensional articles formed therefrom via an additive manufacturing process are provided. The functionalized metallic feedstock includes a plurality of discrete metallic substrates including a first metallic substrate having a first surface area, in which at least a portion of the first surface area comprises a functionalizing agent selected to render the first metallic substrate resistant to corrosion.

Abstract: Metal ceramic composites, or metallic matrix composites (MMCs), may be formed by additive manufacturing (AM) processing of powder beds including a plurality of metallic particles of one or more metals and a plurality of ceramic particles of one or more ceramic materials. The presence of the ceramic particles during the AM process changes the optical properties and/or thermal conductivity of the powder bed since the ceramic particles have markedly different optical properties and/or thermal conductivity relative to metal particles. These optical properties and/or thermal conductivities of the ceramic particles can be tailored in different areas within a given layer of the powder bed to change energy absorption of an energy beam in the different areas. The resulting MMCs exhibit significantly improved performance characteristics, including increases in strength properties, while maintaining ductility and improvement of resistance to pitting and crevice corrosion, among others characteristics.

Abstract: A system provided herein may be configured to evaluate helmet performance. The system may include an impact assembly that includes a stationary post operably coupled to one or more stationary load cells and a plurality of modular headforms. Each modular headform may include a first side and a second side configured to lock together around the impact assembly and receive a helmet. The modular headform may determine a position of the helmet relative to the one or more stationary load cells. Furthermore, the one or more stationary load cells may be configured to measure impact force at a position where one of the plurality of the modular headforms are operably coupled to the impact assembly. Additionally, each of the plurality of modular headforms correspond to a position in relation to the impact assembly to measure the impact force to the one or more load cells at a predefined number of impact locations on the helmet to evaluate the performance of the helmet.

Abstract: Additive manufacturing processes, systems and three-dimensional articles include the formation of voxels and/or portions of three-dimensional articles with different properties relative to other voxels and/or portions. The processes generally include changing one or more laser beam parameters including power level, exposure time, hatch spacing, point distance, velocity, and energy density during the formation of selected voxels and/or portions of the three-dimensional articles. Also disclosed are processes that include an additive manufacturing process that provides localized secondary heat treatment of certain voxels and/or regions at a temperature below the melting point of the three-dimensional article but high enough to effect a localized property change.

Abstract: Electromagnetic shielding systems, apparatuses, and method are provided. One apparatus is an example free-space absorber metamaterial that includes a first array of patches disposed at a first plane, a conductive backplane disposed at a structural surface plane, and a first dielectric spacer disposed between the first array of patches and the conductive backplane. A first bandwidth of absorption for the free-space absorber metamaterial may be based on the area of a patch in the first array of patches, the first electrical resistance of a patch in the first array of patches, and the first gap distance taken between the first array of patches and the conductive backplane.

Abstract: Electromagnetic shielding systems, apparatuses, and method are provided. One apparatus is an example free-space absorber metamaterial that includes a first array of patches disposed at a first plane, a conductive backplane disposed at a structural surface plane, and a first dielectric spacer disposed between the first array of patches and the conductive backplane. A first bandwidth of absorption for the free-space absorber metamaterial may be based on the area of a patch in the first array of patches, the first electrical resistance of a patch in the first array of patches, and the first gap distance taken between the first array of patches and the conductive backplane.