Abstract: A method and system for composite molding, and the method includes additively manufacturing a mold shell that includes a part forming cavity. The method includes filling at least a portion of the mold shell with a strengthening agent. The method includes hardening the strengthening agent to form a mold, and laying-up a composite material on the part forming cavity. The method includes curing the mold to form a composite part.

Abstract: Systems and methods for manufacturing a product include a mixing station for preparing a solution containing a base material and a performance modifier. The base material is configured to deliver performance characteristics of the product that are preselected and the performance modifier is configured to enhance the performance characteristics. An encapsulation station produces particles of the performance modifier in a coating of the base material as an encapsulate powder. An additive manufacturing cell includes an energy source and is used to build the product from the encapsulate powder by an application of energy from the energy source.

Abstract: Low waste methods for three-dimensional printing techniques are provided. A method includes performing a preceding additive infusion process including: solubilizing an additive into a medium in a supercritical fluid state; contacting a preceding material with the medium to infuse a portion of the additive into the preceding material to form a preceding additive-infused material; and separating remaining additive from the medium. Further, the method includes performing at least one succeeding additive infusion process including: solubilizing the remaining additive and, optionally, additional additive, into the medium in a supercritical fluid state; and contacting a succeeding material with the medium to infuse at least a portion of the remaining and additional additive into the succeeding material to form a succeeding additive-infused material, wherein the medium from the preceding additive infusion process is reused in the at least one succeeding additive infusion process.

Abstract: Systems and methods are provided for building a product by additive manufacturing and creating hollow volumes without including build supports in the hollow volume for the layers above the hollow volume. An additive manufacturing cell includes a material handling device, a printer a material delivery system and an energy source to feed the sheets, print on the sheets, apply a powder on the printed sheets, build a hollow volume into the sheets and consolidate the sheets into a product with a contiguous structure.

Abstract: Presented are hybrid fixture assemblies with integrated additive manufactured features, methods for making/using such fixtures, and manufacturing systems equipped with such fixtures. A manufacturing fixture assembly includes a fixture support frame formed, at least in part, from a first material, and a fixture support shell formed, at least in part, from a second material distinct from the first material. The support frame, which seats on/mounts to a work surface, includes a skeletal substructure with multiple male connectors projecting therefrom. The skeletal substructure contains multiple first frame walls that are removably intermeshed with multiple second frame walls in a collapsible format. The support shell includes a support surface that holds a workpiece, an interface surface that abuts the skeletal substructure, and multiple female connectors that project from the interface surface.

Abstract: Protective sleeves, kits-of-parts for manufacturing sleeves, and methods for manufacturing sleeves are provided. An exemplary protective sleeve includes an inlet end connector; intermediate linking connectors; and an outlet end connector. The intermediate linking connectors are interconnected in a series from the inlet end connector to the outlet end connector; and the inlet end connector, the intermediate linking connectors, and the outlet end connector comprise fire-resistant material.

Abstract: A method to manufacture a ceramic foam filter includes: sintering a filter body to a temperature greater than a molten metal to be filtered through the body; creating multiple tortuous path channels extending through the filter body individually having a repeated and controlled passage geometry creating a continuously changing diameter and area of a flow path through the multiple tortuous path channels causing localized increases and decreases in molten metal flow rate through the multiple tortuous path channels; and applying a mixture of at least one ceramic powder and at least one binder using additive manufacturing to shape the filter body including the multiple tortuous path channels.

Abstract: Presented are hybrid fixture assemblies with integrated additive manufactured features, methods for making/using such fixtures, and manufacturing systems equipped with such fixtures. A manufacturing fixture assembly includes a fixture support frame formed, at least in part, from a first material, and a fixture support shell formed, at least in part, from a second material distinct from the first material. The support frame, which seats on/mounts to a work surface, includes a skeletal substructure with multiple male connectors projecting therefrom. The skeletal substructure contains multiple first frame walls that are removably intermeshed with multiple second frame walls in a collapsible format. The support shell includes a support surface that holds a workpiece, an interface surface that abuts the skeletal substructure, and multiple female connectors that project from the interface surface.

Abstract: Systems and methods are provided for cleaning surfaces of a workpiece. The system includes a housing defining an enclosure, a holding structure within the enclosure that is configured to support a workpiece, a first powder removal device that is configured to propel a first media toward the holding structure such that the first media contacts the workpiece while the workpiece is supported by the holding structure, a first sensing device that is configured to detect surface characteristics of the workpiece while the workpiece is supported by the holding structure, and a controller configured to, by a processor: detect a powder material on a surface of the workpiece based on the surface characteristics, and selectively operate the first powder removal device to remove the powder material from the surface with the first media while the workpiece is supported by the holding structure.

Abstract: A composite panel comprises a first skin and a second skin. A core is arranged between and attached to the first skin and the second skin. The core includes Z zones that are 3D printed using a thermoplastic material. Each of the Z zones abuts and is connected to another one of the Z zones. Each of the Z zones has one of D densities and at least one of the Z zones had a different density that another one of the Z zones. Z and D are integers greater than one.

Abstract: Methods for forming a function-infused feed material for a three-dimensional printing technique, methods for manufacturing an additive-infused three-dimensional printed object, and vehicles including additive manufactured components are provided. An exemplary method for forming a function-infused feed material for a three-dimensional printing technique includes solubilizing a functional additive into a medium. Further, the method includes contacting a three-dimensional printing feed material with the medium to infuse the functional additive into the three-dimensional printing feed material to form the function-infused feed material.

Abstract: Low waste methods for three-dimensional printing techniques are provided. A method includes performing a preceding additive infusion process including: solubilizing an additive into a medium in a supercritical fluid state; contacting a preceding material with the medium to infuse a portion of the additive into the preceding material to form a preceding additive-infused material; and separating remaining additive from the medium. Further, the method includes performing at least one succeeding additive infusion process including: solubilizing the remaining additive and, optionally, additional additive, into the medium in a supercritical fluid state; and contacting a succeeding material with the medium to infuse at least a portion of the remaining and additional additive into the succeeding material to form a succeeding additive-infused material, wherein the medium from the preceding additive infusion process is reused in the at least one succeeding additive infusion process.

Abstract: Methods for manufacturing three-dimensional objects using an additive manufacturing technique, methods for forming dye-infused feed material for an additive manufacturing technique, and vehicles including additive manufactured components are provided. An exemplary method for manufacturing a three-dimensional object using an additive manufacturing technique includes solubilizing a dye into a medium in the form of a supercritical fluid and contacting a feed material with the medium to infuse the dye into the feed material to form dye-infused feed material. The method further includes locally melting the dye-infused feed material in selected regions of a layer corresponding to a cross-section of a three-dimensional object being formed and solidifying the dye-infused feed material into a solid layer of dye-infused material. Further, the method includes repeating the local melting and solidifying steps to form the three-dimensional object made up of a plurality of solid layers of dye-infused material.

Abstract: Methods for forming a function-infused feed material for a three-dimensional printing technique, methods for manufacturing an additive-infused three-dimensional printed object, and vehicles including additive manufactured components are provided. An exemplary method for forming a function-infused feed material for a three-dimensional printing technique includes solubilizing a functional additive into a medium. Further, the method includes contacting a three-dimensional printing feed material with the medium to infuse the functional additive into the three-dimensional printing feed material to form the function-infused feed material.

Abstract: Products and methods are provided for additive manufacturing of products in a collapsed state for post printing expansion in preparation for use in their intended application. A product includes interconnecting members configured for forming by printing in a collapsed state, with joints between the interconnecting members configured for relative movement of the interconnected members from the collapsed state to an expanded state. The interconnecting members define a larger package size in the expanded state than in the collapsed state. The joints are freely moveable in the collapsed state and are locked in place in the expanded state.

Abstract: A passively activated flow control device including a valve body configured to be mounted in a vehicle. The valve body includes an inlet and an outlet. A valve member is arranged at the valve body for selectively opening and closing flow between the inlet and the outlet. The valve member is responsive to acceleration induced forces on the vehicle to shift from one of an open configuration and a closed configuration toward the other of the open configuration and the closed configuration.

Abstract: A passively activated flow control device including a valve body configured to be mounted in a vehicle. The valve body includes an inlet and an outlet. A valve member is arranged at the valve body for selectively opening and closing flow between the inlet and the outlet. The valve member is responsive to acceleration induced forces on the vehicle to shift from one of an open configuration and a closed configuration toward the other of the open configuration and the closed configuration.

Abstract: A system includes a processor configured to detect a vehicle key and display a key identification on a vehicle display. The processor is also configured to receive a request to export vehicle system and state settings to a key memory. The processor is further configured to access a plurality of predefined settings, designated as key-storable settings, from a vehicle CAN bus, responsive to the request, and transmit the predefined settings to the key, including instructions to store the settings to the key memory.

Abstract: A ceramic foam filter system includes a filter body having multiple tortuous path channels through the filter body to filter a molten liquid. A filter holder configuration defining a canister in a runner passage receives the filter body. An upstream end of the filter body receives the molten liquid having multiple inclusions. A predominant portion of the inclusions are larger than the multiple tortuous path channels and are trapped against the upstream end of the filter body. The multiple tortuous path channels are sized to trap a predominant portion of multiple oxides within the molten liquid as trapped oxides within the filter body. A filtered molten material having the multiple inclusions and the multiple oxides removed is directed from the multiple tortuous path channels as a discharge flow to exit at a downstream end of the filter body.

Abstract: A method to manufacture a ceramic foam filter includes: sintering a filter body to a temperature greater than a molten metal to be filtered through the body; creating multiple tortuous path channels extending through the filter body individually having a repeated and controlled passage geometry creating a continuously changing diameter and area of a flow path through the multiple tortuous path channels causing localized increases and decreases in molten metal flow rate through the multiple tortuous path channels; and applying a mixture of at least one ceramic powder and at least one binder using additive manufacturing to shape the filter body including the multiple tortuous path channels.