Abstract: A system for fabricating a free form structure of a composite material including carbon nanotubes. The system includes a discharge assembly and a composite formation device operatively linked with the discharge assembly. The discharge assembly dispenses a fusing agent such as for example a high energy density emission, a laser emission or a particle beam emission. The composite formation device includes a composite generator and an arranger in operative engagement with a composite generator. The composite generator engages with the fusing agent so as to create a composite nodal element. The composite nodal element includes a matrix and a multiplicity of fibers formed of carbon nanotubes dispersed throughout the matrix. The arranger positions one node relative to another to define the free form structure.

Abstract: A direct manufacturing technique involving rapid solidification processing uses a reaction between a metallic molten pool and a reactant gas in an inert atmosphere to form alloys with improved desired properties. By utilizing rapid solidification techniques, solubility levels are increased resulting in alloys with unique mechanical and physical properties. Laser deposition of alloys in atmospheres of varying reactant content produce compositions with intermingled and significantly improved overall properties.

Abstract: The present invention provides a direct manufacturing process operable to fabricate three-dimensional physical objects. These three-dimensional physical objects have improved mechanical properties over existing direct manufactured objects. The direct manufacturing process includes an extrusion process, a polymer application process, and a solidification process. The extrusion process deposits a thermoplastic polymer in a series of sequential layers wherein the series of sequential layers are deposited in predetermined patterns. The polymer application process applies compatible polymer(s) after the deposition of each thermoplastic layer. The compatible polymer may be applied in a same or different predetermined pattern when compared to that of the previously deposited thermoplastic layer. The compatible polymer diffuses into voids within the thermoplastic layer.

Abstract: A direct manufacturing technique involving rapid solidification processing uses a reaction between a metallic molten pool and a reactant gas in an inert atmosphere to form alloys with improved desired properties. By utilizing rapid solidification techniques, solubility levels can be increased resulting in alloys with unique mechanical and physical properties. Laser deposition of alloys in atmospheres of varying reactant content produce significant strengthening without cracking. In addition, these materials have very high hardness values for hard face coating and functionally graded materials applications.

Abstract: A liquid-state reaction between a titanium molten pool and a fraction of gaseous nitrogen in an inert atmosphere creates an alloy with increased strength and hardness. A direct manufacturing technique involving rapid solidification processing is used rather than conventional casting techniques that require bulk melting of solid-state nitrided powder. By utilizing rapid solidification techniques, solubility levels can be increased resulting in alloys with unique mechanical and physical properties that are unattainable through conventional processing methods. Laser-powder deposition of titanium alloys in atmospheres of varying argon/nitrogen content produce significant strengthening without cracking in atmosphere concentrations as high as approximately 10% nitrogen. Very high hardness values indicate that this material has valuable applications as a hard face coating on titanium structures and in functionally graded materials.