Abstract: A method for predicting distortion of a part during sintering in an additive process includes receiving a computerized representation of a complex geometric part, discretizing the computerized representation of the complex geometric part into a plurality of elements, processing the plurality of elements of the computerized representation of the complex geometric part with a machine-learning model configured to predict a distorted geometry of the complex geometric part in response to a sintering process, wherein the machine-learning model is trained to predict distortion of a set of primitive geometric coupons represented by image data fed into the machine-learning model during training, the set of primitive geometric coupons having fewer geometries than the complex geometric part, the complex geometric part comprises a plurality of geometries corresponding to geometries associated with the set of primitive geometric coupons, and generating a computerized representation of the predicted distorted geometry of t

Abstract: An article of manufacture includes a part structure formed via a first additive manufacturing process and a floating structure within the part structure which is mechanically decoupled from the part structure. The floating structure is formed concurrently with the part structure via the first additive manufacturing process.

Abstract: Methods for manufacturing dual phase soft magnetic components include combining a plurality of soft ferromagnetic particles with a plurality of paramagnetic particles to form a component structure, wherein the plurality of soft ferromagnetic particles each comprise an electrically insulative coating, and, heat treating the component structure to consolidate the plurality of soft ferromagnetic particles with the plurality of paramagnetic particles.

Abstract: A method of manufacturing an erosion-shielded turbine blade includes providing a turbine blade for use with a rotary machine. The turbine blade includes an airfoil extending between a root and a tip. The airfoil includes a pressure side and an opposite suction side, and each of the pressure and suction sides extends between a leading edge and a trailing edge. The method also includes printing a green body part by an additive manufacturing process by selectively depositing a binder solution across a particulate erosion-resistant material, and sintering the green body part to produce a post-sintering erosion shield that includes densified erosion-resistant material. The method also includes coupling the erosion shield to the leading edge of the turbine blade.

Abstract: A method of manufacturing an erosion-shielded turbine blade includes providing a turbine blade for use with a rotary machine. The turbine blade includes an airfoil extending between a root and a tip. The airfoil includes a pressure side and an opposite suction side, and each of the pressure and suction sides extends between a leading edge and a trailing edge. The method also includes printing a green body part by an additive manufacturing process by selectively depositing a binder solution across a particulate erosion-resistant material, and sintering the green body part to produce a post-sintering erosion shield that includes densified erosion-resistant material. The method also includes coupling the erosion shield to the leading edge of the turbine blade.

Abstract: Various embodiments provide a method of additively manufacturing a part including depositing a layer of a powder on a working surface, depositing a binder solution on the layer of the powder at first locations, and depositing a sintering aid solution on the layer of the powder at second locations. The sintering aid solution comprises a sintering aid in a solvent. In various embodiments, the sintering aid enables an increased brown strength as compared to parts containing unbound powder. The method enables binders that provide high green strength to be used at the edges of the part, while also balancing a shortened debind time with an increased brown strength. Embodiments in which binder solution is deposited according to a predetermined pattern at second locations are also described.

Abstract: A method of predicting a post-sintering geometry of a green body part includes determining stress differentiating material properties of a material configuration of the green body part by physically measuring the stress differentiating material properties of the material configuration and identifying a plurality of stress regions in the green body part via a first sintering analysis of the green body part. Each stress region is associated with a portion of the green body part subjected to a particular stress state during sintering. The method also includes assigning different sets of stress differentiating material properties to each of the plurality of stress regions to form a stress-simulated green body part and predicting the post-sintering geometry via a second sintering analysis of the stress-simulated green body part.

Abstract: A method of generating a distortion-compensated geometry for a workpiece includes generating a green body part geometry for the workpiece, discretizing the green body part geometry into a green body part mesh and performing a first sintering analysis on the green body part mesh to generate a post-sintering mesh based on the green body part mesh, the post-sintering mesh including a plurality of post-sintering mesh nodes. The method also includes co-registering the post-sintering mesh and a model mesh having a geometry corresponding to the three-dimensional model, the model mesh including a plurality of model mesh nodes. For each of the plurality of post-sintering mesh nodes, a displacement between a post-sintering mesh node and a corresponding model mesh nodes is determined, and the green body mesh may be adjusted based on the displacement to generate the distortion-compensated geometry.

Abstract: Methods for manufacturing dual phase soft magnetic components include combining a plurality of soft ferromagnetic particles with a plurality of paramagnetic particles to form a component structure, wherein the plurality of soft ferromagnetic particles each comprise an electrically insulative coating, and, heat treating the component structure to consolidate the plurality of soft ferromagnetic particles with the plurality of paramagnetic particles.

Abstract: According to some embodiments, system and methods are provided comprising receiving, via a communication interface of a distortion and correction module comprising a processor, a defined geometry for one or more parts, wherein the parts are manufactured with an additive manufacturing machine; discretizing the defined geometry into a mesh including a plurality of nodes; predicting a distortion of a position of each node of the plurality of nodes; determining whether the predicted distortion position exceeds a pre-set tolerance; determining an adjusted pre-distortion position for each node of the plurality of nodes when the predicted distortion position exceeds the pre-set tolerance; predicting a distortion of the adjusted determined pre-distortion position for each node of the plurality of nodes; determining whether the distortion of the determined adjusted pre-distortion position exceeds the pre-set tolerance; and printing the part when one of the predicted distortion position and the predicted adjusted pre-d

Abstract: A system includes a memory module configured to store a computer model of a part for manufacturing with an additive manufacturing machine, and a processor communicatively coupled to the memory module. The processor is configured to receive the computer model, discretize the computer model into a mesh, predict a deformation behavior the plurality of nodes of the mesh under a simulated sintering process, determine a buckling factor for the part based on the predicted deformation behavior of the mesh, determine whether the buckling factor exceeds a threshold, in response to determining that the buckling factor exceeds the threshold, export the computer model to the additive manufacturing machine for pre-build processing, and in response to determining that the buckling factor does not exceeds the threshold, output, to a display of the system, at least one of an alert that the part is unstable or the buckling factor.

Abstract: Various embodiments provide a method of additively manufacturing a part including depositing a layer of a powder on a working surface, depositing a binder solution on the layer of the powder at first locations, and depositing a sintering aid solution on the layer of the powder at second locations. The sintering aid solution comprises a sintering aid in a solvent. In various embodiments, the sintering aid enables an increased brown strength as compared to parts containing unbound powder. The method enables binders that provide high green strength to be used at the edges of the part, while also balancing a shortened debind time with an increased brown strength. Embodiments in which binder solution is deposited according to a predetermined pattern at second locations are also described.

Abstract: An article of manufacture includes a part structure formed via a first additive manufacturing process and a floating structure within the part structure which is mechanically decoupled from the part structure. The floating structure is formed concurrently with the part structure via the first additive manufacturing process.

Abstract: A system includes a memory module configured to store a computer model of a part for manufacturing with an additive manufacturing machine, and a processor communicatively coupled to the memory module. The processor is configured to receive the computer model, discretize the computer model into a mesh, predict a deformation behavior the plurality of nodes of the mesh under a simulated sintering process, determine a buckling factor for the part based on the predicted deformation behavior of the mesh, determine whether the buckling factor exceeds a threshold, in response to determining that the buckling factor exceeds the threshold, export the computer model to the additive manufacturing machine for pre-build processing, and in response to determining that the buckling factor does not exceeds the threshold, output, to a display of the system, at least one of an alert that the part is unstable or the buckling factor.

Abstract: An article of manufacture includes a part structure formed via a first additive manufacturing process and a floating structure within the part structure which is mechanically decoupled from the part structure. The floating structure is formed concurrently with the part structure via the first additive manufacturing process.

Abstract: A method of predicting a post-sintering geometry of a green body part includes determining stress differentiating material properties of a material configuration of the green body part by physically measuring the stress differentiating material properties of the material configuration and identifying a plurality of stress regions in the green body part via a first sintering analysis of the green body part. Each stress region is associated with a portion of the green body part subjected to a particular stress state during sintering. The method also includes assigning different sets of stress differentiating material properties to each of the plurality of stress regions to form a stress-simulated green body part and predicting the post-sintering geometry via a second sintering analysis of the stress-simulated green body part.

Abstract: A method of generating a distortion-compensated geometry for a workpiece includes generating a green body part geometry for the workpiece, discretizing the green body part geometry into a green body part mesh and performing a first sintering analysis on the green body part mesh to generate a post-sintering mesh based on the green body part mesh, the post-sintering mesh including a plurality of post-sintering mesh nodes. The method also includes co-registering the post-sintering mesh and a model mesh having a geometry corresponding to the three-dimensional model, the model mesh including a plurality of model mesh nodes. For each of the plurality of post-sintering mesh nodes, a displacement between a post-sintering mesh node and a corresponding model mesh nodes is determined, and the green body mesh may be adjusted based on the displacement to generate the distortion-compensated geometry.

Abstract: An industrial asset item definition data store may contain at least one electronic record defining the industrial asset item. An automated support structure creation platform may include a support structure optimization computer processor. The automated support structure optimization computer processor may be adapted to automatically create support structure geometry data associated with an additive printing process for the industrial asset item. The creation may be performed via an iterative loop between a build process simulation engine and a topology optimization engine.

Abstract: A method, medium, and system to receive a specification defining a model of a part to be produced by an additive manufacturing (AM) process; execute an AM simulation on the model of the part to determine a prediction of thermal distortions to the part; execute a topology optimization (TO) to create TO supports that counteract the predicted thermal distortions; generate at least one rule-based support based on a geometry of the part to interface with the part at one or more regions other than the TO supports; combining the TO supports and the at least one rule-based support to generate a set of hybrid supports; save a record of the set of hybrid supports; and transmit the record of the set of hybrid supports to an AM controller to control an AM system to generate a support structure for an AM production of the part.

Abstract: A method and system to receive a specification defining a model of a part to be produced by an additive manufacturing (AM) process; define a design space to enclose the part and a support structure for the part, the support structure to support the part and printed with the part during the AM process; execute an iterative topology optimization(TO) based at least in part on the specification for the part and the defined design space, to generate a TO support structure that counteracts predicted gravity-based distortions during the AM process; save a record of the generated TO support structure; and transmit the record of the TO support structure to an AM controller, the AM controller to control an AM system to generate an instance of the part and the TO support structure based on the record.