Abstract: A test specimen is provided. The test specimen includes a coupon. The coupon includes a test portion and grip portions. The grip portions are located on opposite axial ends of the coupon. The test portion is located between the grip portions. The coupon further includes a void extending into the coupon from at least one of the axial ends. The void is defined by a wall having a surface thickness at the test portion that corresponds to a predetermined surface thickness of interest. The coupon is configured to be secured to a test machine for conducting load tests on the coupon.

Abstract: A test specimen is provided. The test specimen includes a coupon. The coupon includes a test portion and grip portions. The grip portions are located on opposite axial ends of the coupon. The test portion is located between the grip portions. The coupon further includes a void extending into the coupon from at least one of the axial ends. The void is defined by a wall having a surface thickness at the test portion that corresponds to a predetermined surface thickness of interest. The coupon is configured to be secured to a test machine for conducting load tests on the coupon.

Abstract: A passive non-ablating thermally protective structure body is disclosed. An improved-reliability heat pipe edge comprises a non-porous material formed into a wedge-shaped chamber, and a porous layer. The porous layer extends from interior surfaces of the non-porous material to provide capillary wicking.

Abstract: Systems and methods of reproducing images onto surfaces are disclosed. In one embodiment, the system includes an image file that digitally produces a planar surface normal to a surface of a master model. The planar surfaces are referenced to a coordinate system of the master model through a series of points. A tracker surfacing system, comprising a tracking instrument, generates and emits a signal as the tracking instrument crosses the planar surface. An output device is actuated by the tracking device as it crosses the planar surface, reproducing the series of points as an image onto a surface, including a flat, curved or compound surface. Both the spatial position and orientation of the output device are detected and adjustments are made so that the image is precisely applied to intended locations on the surface being imaged.

Abstract: A metal powder production system includes a vacuum chamber having a vacuum chamber interior, a stock feed mechanism communicating with the vacuum chamber interior, a radiation source provided in the vacuum chamber interior, a cooling chamber having a cooling chamber interior communicating with the vacuum chamber interior and a container communicating with the cooling chamber interior. A metal powder production method is also disclosed.

Abstract: A metal powder production system includes a vacuum chamber having a vacuum chamber interior, a stock feed mechanism communicating with the vacuum chamber interior, a radiation source provided in the vacuum chamber interior, a cooling chamber having a cooling chamber interior communicating with the vacuum chamber interior and a container communicating with the cooling chamber interior. A metal powder production method is also disclosed.

Abstract: In an embodiment of the invention, there is provided a method of making a heat exchanger core component comprising the steps of generating a stereolithography file from design data, slicing the stereolithography file into two-dimensional patterns, repeating the two-dimensional patterns sequentially to produce a three-dimensional core component, and depositing at least one layer of a material having a high thermal conductivity onto a top surface of a base. In another embodiment there is provided a heat exchanger core component made by an embodiment of the method wherein the core component comprises a triply periodic design that is repeated in three dimensions.

Abstract: A monitoring device and method is disclosed for monitoring the saturation level of resin in solvent baths, such as those used to remove resin from objects form by stereolithography. The monitoring device operates by monitoring an electrical characteristic, such as impedance, of the solvent bath as the resin-to-solvent ratio of the bath increases during use. Signals are provided by the monitoring device to the operator of the liquid storage device containing the solvent bath in a manner allowing the operator to determine when the solvent bath has reached the end of its useful life.

Abstract: A method of using a minimal surface or a minimal skeleton to make a heat exchanger component is provided. The method comprises the steps of generating a stereolithography file from design data, slicing the stereolithography file into two-dimensional patterns, repeating the two-dimensional patterns sequentially to produce a three-dimensional minimal surface component or minimal skeleton component, and depositing at least one layer of a material having a high thermal conductivity onto a top surface of a base, wherein the deposited material forms either a three-dimensional minimal surface component or a three-dimensional minimal skeleton component. Also provided are the heat exchanger components made by the embodiments of the method using either minimal surfaces or minimal skeletons.

Abstract: A metal powder production system includes a vacuum chamber having a vacuum chamber interior, a stock feed mechanism communicating with the vacuum chamber interior, a radiation source provided in the vacuum chamber interior, a cooling chamber having a cooling chamber interior communicating with the vacuum chamber interior and a container communicating with the cooling chamber interior. A metal powder production method is also disclosed.

Abstract: In one embodiment, a method of making a heat exchanger is provided, comprising the steps of generating a stereolithography file from design data, slicing the stereolithography file into two-dimensional patterns, and depositing at least one layer of a material having a high thermal conductivity onto a top surface of a substrate to form a heat exchanger. Preferably, the heat exchanger does not require assembly of separate pieces to form the heat exchanger. In another embodiment a heat exchanger made by this embodiment of the method is provided wherein the heat exchanger may have a design comprising tapered fins and/or alternating airfoil cross-sections.

Abstract: A method of making a layered component with an improved surface finish by a shape metal deposition process is provided. The method comprises the steps of discriminating a first set of vectors on an exterior portion of the component from a second set of vectors on an interior portion of the component, and depositing a layer of metal material based on the vectors discriminated at different rates, wherein the material is deposited on the exterior portion at a high resolution and a slow rate, and the material is deposited on the interior portion at a low resolution and a fast rate.

Abstract: The invention is directed to a method of making improved net-shaped components by a hybrid metal deposition process for either hot or cold metals. The method involves using a metal deposition machine to deposit at least one layer of a metal alloy onto a top surface of a substrate to form a component part, and to cut the component part with a cutting component, such as an electron beam gun to form a predetermined net-shaped component part. Preferably, the number of layers deposited equals the number of layers cut.

Abstract: A method for the direct manufacture of aerospace duct elements is provided comprising executing a single build run on a build chamber using direct fabrication technology to generate at least one duct section. The at least one duct section is generated by forming a plurality of partial cylinder duct segments orientated within the build chamber in a nested arrangement during the single build run, and assembling at least two of the partial cylinder duct segments to form the duct section. During the single build run a plurality of stiffening protrusions are formed on each of the partial cylinder duct segments to improve duct rigidity and to modify flow through the duct section.

Abstract: A metal powder production system includes a vacuum chamber having a vacuum chamber interior, a stock feed mechanism communicating with the vacuum chamber interior, a radiation source provided in the vacuum chamber interior, a cooling chamber having a cooling chamber interior communicating with the vacuum chamber interior and a container communicating with the cooling chamber interior. A metal powder production method is also disclosed.

Abstract: In accordance with the present invention a method for the direct manufacture of aerospace duct elements is provided comprising executing a single build run on a build chamber using direct fabrication technology to generate at least one duct section. The at least one duct section is generated by forming a plurality of partial cylinder duct segments orientated within the build chamber in a nested arrangement during the single build run, and assembling at least two of the partial cylinder duct segments to form the duct section. The duct section has a duct cross-sectional profile larger than a build chamber profile.

Abstract: In an embodiment of the invention, there is provided a method of making a heat exchanger core component comprising the steps of generating a stereolithography file from design data, slicing the stereolithography file into two-dimensional patterns, repeating the two-dimensional patterns sequentially to produce a three-dimensional core component, and depositing at least one layer of a material having a high thermal conductivity onto a top surface of a base. In another embodiment there is provided a heat exchanger core component made by an embodiment of the method wherein the core component comprises a triply periodic design that is repeated in three dimensions.

Abstract: A method of using a minimal surface or a minimal skeleton to make a heat exchanger component is provided. The method comprises the steps of generating a stereolithography file from design data, slicing the stereolithography file into two-dimensional patterns, repeating the two-dimensional patterns sequentially to produce a three-dimensional minimal surface component or minimal skeleton component, and depositing at least one layer of a material having a high thermal conductivity onto a top surface of a base, wherein the deposited material forms either a three-dimensional minimal surface component or a three-dimensional minimal skeleton component. Also provided are the heat exchanger components made by the embodiments of the method using either minimal surfaces or minimal skeletons.

Abstract: In one embodiment, a method of making a heat exchanger is provided, comprising the steps of generating a stereolithography file from design data, slicing the stereolithography file into two-dimensional patterns, and depositing at least one layer of a material having a high thermal conductivity onto a top surface of a substrate to form a heat exchanger. Preferably, the heat exchanger does not require assembly of separate pieces to form the heat exchanger. In another embodiment a heat exchanger made by this embodiment of the method is provided wherein the heat exchanger may have a design comprising tapered fins and/or alternating airfoil cross-sections.

Abstract: A method of making a layered component with an improved surface finish by a shape metal deposition process is provided. The method comprises the steps of discriminating a first set of vectors on an exterior portion of the component from a second set of vectors on an interior portion of the component, and depositing a layer of metal material based on the vectors discriminated at different rates, wherein the material is deposited on the exterior portion at a high resolution and a slow rate, and the material is deposited on the interior portion at a low resolution and a fast rate.