Abstract: A method of additively manufacturing an object includes successively forming a plurality of powder layers by depositing powder over a build platform using a powder-deposition apparatus. The method also includes successively forming a binder shell by bonding select regions of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers using a binder-delivery apparatus. The binder shell encloses a portion of the powder. The method further includes densifying the portion of the powder bound by the binder shell using a consolidation apparatus.

Abstract: A method of additively manufacturing an object includes successively forming a plurality of powder layers by depositing powder over a build platform using a powder-deposition apparatus. The method also includes successively forming a binder shell by bonding select regions of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers using a binder-delivery apparatus. The binder shell encloses a portion of the powder. The method further includes densifying the portion of the powder bound by the binder shell using a consolidation apparatus.

Abstract: A method of additively manufacturing an object includes steps of: (1) selectively depositing build powder inside of a build contour of the object to form a build-powder section of a powder layer; and (2) selectively depositing support powder outside of the build contour to form a support-powder section of the powder layer. According to the method, the build powder includes a build-powder composition, the support powder includes a support-powder composition, and the build-powder composition and the support-powder composition are different.

Abstract: A powder-deposition apparatus for an additive manufacturing system includes a recoater, a mixer, and a powder feeder. The recoater is configured to discharge powder such that a powder layer is formed from the powder. The mixer is configured to mix a plurality of powder constituents to produce the powder and to dispense the powder to the recoater. The powder feeder is configured to selectively dispense a mass of each one of the plurality of powder constituents to the mixer such that a composition of the powder is selectively controlled.

Abstract: A method of additively manufacturing an object includes steps of: (1) successively forming a plurality of powder layers by depositing powder; (2) selectively controlling a composition of the powder that forms each one of the plurality of powder layers; and (3) successively forming a plurality of object layers of the object by joining the powder of a portion of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers.

Abstract: An article comprising additively manufactured metal portions is described. The article comprises a first additively manufactured metal portion, and a second additively manufactured metal portion coupled to the first additively manufactured metal portion at a welded joint. The article further comprises a resistive heating material disposed within an interior of the welded joint, the resistive heating material comprising a different material than the first additively manufactured metal portion and the second additively manufactured metal portion.

Abstract: A method of additively manufacturing an object includes successively forming a plurality of powder layers by depositing powder over a build platform using a powder-deposition apparatus. The method also includes successively forming a binder shell by bonding select regions of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers using a binder-delivery apparatus. The binder shell encloses a portion of the powder. The method further includes densifying the portion of the powder bound by the binder shell using a consolidation apparatus.

Abstract: A system for spraying a coating material to a substrate includes an optical sensor that monitors a thickness, a controller that generates a first signal corresponding to an amount of gas propellant to be heated, a second signal corresponding to a temperature to which the gas propellant is to be heated, a third signal corresponding to an amount of a solid powder composition to be mixed with the heated gas, and a fourth signal corresponding to a distance between the nozzle and the substrate, a first regulator that supplies an amount of gas propellant corresponding to the first signal, a heater that heats the gas propellant to the temperature corresponding to the second signal, a second regulator that supplies an amount of solid powder composition corresponding to the third signal, and an actuator that moves the nozzle corresponding to the fourth signal.

Abstract: A method for fabricating an electrical conductor on a substrate by cold spraying includes propelling a solid powder composition that includes copper and highly oriented pyrolytic graphite using a gas propellant, and directing the solid powder composition towards the substrate at a velocity sufficient to cause the solid powder composition to undergo plastic deformation and to adhere to the substrate to deposit the electrical conductor thereon.

Abstract: An article comprising additively manufactured metal portions is described. The article comprises a first additively manufactured metal portion, and a second additively manufactured metal portion coupled to the first additively manufactured metal portion at a welded joint. The article further comprises a resistive heating material disposed within an interior of the welded joint, the resistive heating material comprising a different material than the first additively manufactured metal portion and the second additively manufactured metal portion.

Abstract: A method of additively manufacturing an object includes steps of: (1) successively forming a plurality of powder layers by depositing powder; (2) selectively controlling a composition of the powder that forms each one of the plurality of powder layers; and (3) successively forming a plurality of object layers of the object by joining the powder of a portion of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers.

Abstract: A method of additively manufacturing an object includes steps of: (1) selectively depositing build powder inside of a build contour of the object to form a build-powder section of a powder layer; and (2) selectively depositing support powder outside of the build contour to form a support-powder section of the powder layer. According to the method, the build powder includes a build-powder composition, the support powder includes a support-powder composition, and the build-powder composition and the support-powder composition are different.

Abstract: An article comprising additively manufactured metal portions is described. The article comprises a first additively manufactured metal portion, and a second additively manufactured metal portion coupled to the first additively manufactured metal portion at a welded joint. The article further comprises a resistive heating material disposed within an interior of the welded joint, the resistive heating material comprising a different material than the first additively manufactured metal portion and the second additively manufactured metal portion.

Abstract: A method for fabricating an electrical conductor on a substrate by cold spraying includes propelling a solid powder composition that includes copper and highly oriented pyrolytic graphite using a gas propellant, and directing the solid powder composition towards the substrate at a velocity sufficient to cause the solid powder composition to undergo plastic deformation and to adhere to the substrate to deposit the electrical conductor thereon.

Abstract: A carbon nanomaterial composite sheet and a method for making a carbon nanomaterial composite sheet may include a layer of a carbon nanomaterial structure being bonded to a carrier layer, the carrier layer being fabricated from a porous metalized nonwoven material.

Abstract: A method for making a conductive pre-impregnated composite sheet includes the steps of joining a nanomaterial composite sheet, a fiber-reinforcing sheet and a resin system to form a combined sheet, heating the combined sheet, compacting the combined sheet, and cooling the combined sheet to form conductive pre-impregnated composite sheet including the fiber-reinforcing sheet, and the nanomaterial composite sheet coupled to the fiber-reinforcing sheet, wherein the fiber-reinforcing sheet and the nanomaterial composite sheet are embedded in the resin system.

Abstract: A transmission cable may include a conductor core, an insulator layer surrounding the conductor core, and a shielding layer surrounding the insulator layer, wherein the shielding layer includes a carbon nanotube sheet material.

Abstract: A system and method for producing a uniform continuous fiber filament. The system and method include a fiber tow with an axial magnet attached to an end of the fiber tow, a polymer tube, and a radial magnet that fits around a circumference of the polymer tube. The radial and axial magnets are used to feed the fiber tow through the polymer tube using magnetic forces to create the uniform continuous fiber filament.

Abstract: A method for making a conductive pre-impregnated composite sheet includes the steps of joining a nanomaterial composite sheet, a fiber-reinforcing sheet and a resin system to form a combined sheet, heating the combined sheet, compacting the combined sheet, and cooling the combined sheet to form conductive pre-impregnated composite sheet including the fiber-reinforcing sheet, and the nanomaterial composite sheet coupled to the fiber-reinforcing sheet, wherein the fiber-reinforcing sheet and the nanomaterial composite sheet are embedded in the resin system.

Abstract: A frequency-selective composite structure includes a laminate panel, and a frequency-selective filter including a plurality of frequency-selective surface elements coupled to an exterior surface of the laminate panel and arranged in a frequency-selective surface pattern, wherein each one of the frequency-selective surface elements includes a nanomaterial composite.