Abstract: A method of forming a composite includes providing a plurality of metallic particles having a nano-crystalline microstructure. The method includes selecting an internal microstructure of the metallic particles to be present in the composite and determining a processing temperature in response to the selected internal microstructure. The method includes heating an amalgamation of the metallic particles and a polymer to the processing temperature and extruding the heated amalgamation through a printer nozzle to form the composite.

Abstract: A composite material includes a plurality of metallic particles formed through modulation-assisted machining. The composite includes a thermoplastic polymer matrix which binds the plurality of metallic particles.

Abstract: A composite material includes a plurality of metallic particles formed through modulation-assisted machining. The composite includes a thermoplastic polymer matrix which binds the plurality of metallic particles.

Abstract: A modulating tool holder includes a tool holder first end and a tool holder second end, and a central axis extending between the tool holder first end and the tool holder second end. The tool holder first end has a coupler for coupling the tool holder to a drive member of a machining device and the second end includes a clamp for releasably holding either a tool or a workpiece. A rotatable spindle member extends axially in the tool holder and imparts a rotational movement to the clamp. A central fluid passageway extends between first and second ends of the rotatable spindle member for conveying a fluid. A linear actuator is configured to impart an oscillating movement to the clamp. The linear actuator is functionally decoupled from the torsional load of the rotatable spindle member.

Abstract: A method is provided for controlling a machining operation wherein a tool performs a machining operation on a workpiece. The method includes providing a tool holder for holding a tool, a workpiece holder for holding a work piece, and a linear slide for linearly moving a linearly moving part that is either the tool or the workpiece. The step of selecting appropriate machining parameters includes the step of selecting an appropriate feed rate for the linear slide move the linear moving part and appropriate rotational speed is selected for the rotator to rotate the rotating part. The set of appropriate machining parameters are incorporated into the digital controller. The digital controller is then used to control the operation of a linear slide, rotator and modulator to execute the machining of the workpiece by the tool in accordance with a selected appropriate set of parameters.