Abstract: Methods and systems are described for fabricating a component using 3D printing. A 3D printed piece is created including a body of the component, a support structure, and a first sacrificial interface region coupling the body of the component to the support structure. The body of the component is formed of a first metal or ceramic material and the first sacrificial interface region is formed at least partially of a second metal or ceramic material. The body of the component is then separated from the support structure by applying a chemical or electrochemical dissolution process to the 3D printed piece. Because the second metal or ceramic material is less resistant to the dissolution process than the first metal or ceramic material, the first sacrificial interface region at least partially dissolves, thereby separating the body of the metal component from the support structure, without dissolving the body of the component.

Abstract: Systems and methods are disclosed for fabricating a metal or ceramic component using a 3D printer. An entire 3D printed piece, including both the metal or ceramic component and one or more support structures, is created of a first metal or ceramic material. A sensitization layer is applied to all or part of the 3D printed piece to chemically alter portions of the first metal or ceramic material near the surface making those portions of the material more sensitive to the etching process. The etching process causes the affected material to deplete and separates the component from the support structures without requiring mechanical machining.

Abstract: Methods and systems are described for fabricating a component using 3D printing. A 3D printed piece is created including a body of the component, a support structure, and a first sacrificial interface region coupling the body of the component to the support structure. The body of the component is formed of a first metal or ceramic material and the first sacrificial interface region is formed at least partially of a second metal or ceramic material. The body of the component is then separated from the support structure by applying a chemical or electrochemical dissolution process to the 3D printed piece. Because the second metal or ceramic material is less resistant to the dissolution process than the first metal or ceramic material, the first sacrificial interface region at least partially dissolves, thereby separating the body of the metal component from the support structure, without dissolving the body of the component.

Abstract: Systems and methods are disclosed for fabricating a metal or ceramic component using a 3D printer. An entire 3D printed piece, including both the metal or ceramic component and one or more support structures, is created of a first metal or ceramic material. A sensitization layer is applied to all or part of the 3D printed piece to chemically alter portions of the first metal or ceramic material near the surface making those portions of the material more sensitive to the etching process. The etching process causes the affected material to deplete and separates the component from the support structures without requiring mechanical machining.

Abstract: Systems and methods are described for fabricating a metal or ceramic component using 3D printing. A 3D printed piece is created that includes a body of the component and a support structure. While the 3D printed piece is created using a single printing material, one or more processing parameters are adjusted while printing a first sacrificial interface region coupling the body of the component to the support structure. The body of the component is separated from the support structure by applying a chemical or electrochemical dissolution process to the 3D printed piece. The adjustment to the one or more processing parameters during printing of the first sacrificial interface region creates a localized area that is less resistant to the chemical or electrochemical dissolution process than the body of the component.

Abstract: A method is described for making a frozen French fry-style food product, having from about 50.0% to about 70.0% moisture, from about 4.0% to about 8.0% protein, from about 2.5% to about 5.0% fat, and from about 0.25% to about 0.50% fibers, in addition to calcium and phosphorous sources. This frozen potato-based product is made from a composition comprising steam peeled and cooked whole raw potatoes, soaked or cooked whole beans processed and mixed with the peeled cooked potatoes to create a dough-like consistency to which proteinaceous flours, starchy flours, vegetable oil, and other additives are added and blended into a homogeneous potato-based dough. The homogeneous potato-based dough is extruded into a rope-like extrudate, which is partially steam-cooked and then immediately cooled. The cold rope-like extrudate is cut into uniform small rods, 2.5 inches long, which are packaged and stored under blast freezing conditions.

Abstract: A method is described for making a frozen French fry-style food product, having from about 50.0% to about 70.0% moisture, from about 4.0% to about 8.0% protein, from about 2.5% to about 5.0% fat, and from about 0.25% to about 0.50% fibers, in addition to calcium and phosphorous sources. This frozen potato-based product is made from a composition comprising of steam peeled and cooked whole raw potatoes, soaked or cooked whole beans processed and mixed with the peeled cooked potatoes to create a dough-like consistency to which proteinatious flours, starchy flours, vegetable oil, and other additives are added and blended into a homogeneous potato-based dough. The homogeneous potato-based dough is extruded into a rope-like extrudate which is partially steam-cooked at a desired temperature, then immediately cooled down to a desired temperature. The cold rope-like extrudate is cut into uniform small rods, 2.5 inches long, which are packaged and stored under blast freezing conditions.

Abstract: A method is described for producing extruded French Fries-Style products from dough containing between 45% to 50% moisture, from 4% to 8% protein, and from 0.25% to 0.5% fibers. Said dough is composed of steam-peeled potatoes soaked beans, desired spices, flavors, colors, and fortified with vitamins and minerals. The dough is pumped under vacuum to specific forming heads containing openings of desired shapes and dimensions. The continuous extrudate coming from said forming heads is received over a solid conveying belt traveling inside a steam-heated path at an adjusted speed to expose the extrudate to steam for a certain length of time to bring the temperature of the center of the extrudate from 140 to 190 degrees Fahrenheit. The extrudate is then received over a belt-conveyer traveling inside a freezing-tunnel where it is exposed to blasts of cooled air for a period of time to lower the temperature of the extrudate to 45 and degrees Fahrenheit or lower.

Abstract: A method is described for producing extruded French Fries-Style products from dough containing between 45% to 50% moisture, from 4% to 8% protein, and from 0.25% to 0.5% fibers. Said dough is composed of steam-peeled potatoes over-night soaked beans, desired spices, flavors, colors, and fortified with vitamins and minerals, also containing suitable anti-oxidant agents. Said dough is pumped under vacuum to specific forming heads containing openings of desired shapes and dimensions. The continuous extrudate coming from said forming head is received over a solid conveying belt traveling inside a steam-heated path at an adjusted speed to expose the extrudate to steam for a certain length of time enough to bring the temperature of the center of the extrudate from 140 to 190 degrees Fahrenheit.