Abstract: Systems and methods are disclosed for forming a three-dimensional object using additive manufacturing. One method includes depositing a first amount of powder material onto a powder print bed of a printing system, spreading the first amount of powder material across the powder print bed to form a first layer, measuring a density of powder material within the powder print bed, and adjusting a parameter of the printing system based on the measured density of the powder material within the powder print bed.

Abstract: A method for improving part quality in additive manufacturing involving jetting liquid metal. Limiting the amounts of magnesium and zinc in a meniscus material to below predetermined thresholds improves jetting quality. Further, ensuring an amount of Strontium is above a predetermined threshold further improves jetting of the liquid metal.

Abstract: Embodiments related to solar modules and their manufacture are disclosed. In one embodiment, a solar module may include first and second solar cells with first and second interconnection wires disposed on upper and lower surfaces of one and/or both of the solar cells, and a cross-connect wire disposed between the solar cells and electrically connected to the first and second interconnection wires. A portion of each of the first and second interconnection wires may be removed to electrically isolate the upper surfaces from the lower surfaces of each solar cell while retaining an electrical connection between the upper surface of one cell with the lower surface of the adjoining solar cell through the cross-connect wire. In some embodiments, the first and second interconnection wires may be arranged as a plurality of offset wires located on opposing sides of the solar cells which may reduce stresses applied to the solar cells.

Abstract: The present invention relates to methods for the formation of ceramic bodies. Methods of the invention involve processing ceramic-forming compositions to form an integrally self-supporting or stabilized structure, which may then be sintered to give the full-density ceramic product. Methods of the invention may also involve densification of the ceramic body. In one set of embodiments, the volume of the integrally self-supporting structure is reduced by at least 20%. The present invention may produce ceramic bodies having greater strength and durability, since the ceramic-forming compositions may be low in viscosity and may be homogeneously blended, decreasing the possibility for defects.

Abstract: A method and apparatus for growing a crystalline or poly-crystalline body from a melt is described, wherein the melt is retained by capillary attachment to edge features of a mesa crucible. The boundary profile of the resulting melt surface results in an effect which induces a ribbon grown from the surface of the melt to grow as a flat body. Further, the size of the melt pool is substantially reduced by bringing these edges close to the ribbon, thereby reducing the materials cost and electric power cost associated with the process.

Abstract: Methods of manufacturing an article use three-dimensional printing for a portion of the manufacturing. Three-dimensionally printing is conducted onto a powder bed which contains both organic-solvent-soluble, water-insoluble particles and water soluble, organic-solvent-insoluble particles. The water-soluble particles which may be selected for properties such as size and may include more than one substance. The organic-solvent-insoluble particles may further include at least one substantially insoluble substance such as a member of the calcium phosphate family. Printing may be done using an aqueous binder liquid. After removal of unbound powder, the preform may be exposed to the vapor of an organic solvent which causes the particles of organic-soluble-polymer to fuse to each other. This may further be followed by dissolving out the water-soluble particles, if such particles were present in the powder.

Abstract: The present invention relates to methods for the formation of ceramic bodies. Methods of the invention involve processing ceramic-forming compositions to form an integrally self-supporting or stabilized structure, which may then be sintered to give the full-density ceramic product. Methods of the invention may also involve densification of the ceramic body. In one set of embodiments, the volume of the integrally self-supporting structure is reduced by at least 20%. The present invention may produce ceramic bodies having greater strength and durability, since the ceramic-forming compositions may be low in viscosity and may be homogeneously blended, decreasing the possibility for defects.

Abstract: Crystalline silicon PV modules typically use tinned flat copper wire to increase the conductivity of a bus bar metallization and to interconnect to adjacent cells. Such a flat bus wire may be patterned with shallow v-shaped grooves using metal forming techniques, such as rolling, stamping and drawing. The grooves are designed so that incident light is reflected up toward the glass superstrate of the module at an internal interface angle that is large enough (typically greater than about 40°) so that the light undergoes total internal reflection at the glass-air interface and is reflected onto the solar cell. A photocurrent resulting from the normal impingement of light on a proto-type of such a patterned bus bar is at least 70% of the photocurrent resulting from the direct impingement on active cell area of the same light source. A typical face angle of about 60° may provide TIR for at least 50% of the light that strikes the bus wire as omni-directional illumination.

Abstract: The invention includes biostructures which may be characterized as having substantially all of the organic-solvent-soluble material in the form of a network of irregularly shaped perforated films. The biostructure may further include particles of a substantially-insoluble material, which may be a member of the calcium phosphate family. The biostructure may be osteoconductive. The biostructure may further contain an Active Pharmaceutical Ingredient or other bioactive substance. The API may be a substance which stimulates the production of bone morphogenetic protein, such as Lovastatin or related substances, thereby making the biostructure effectively osteoinductive. One or more of the polymers may have a resorption rate in the human body such as to control the release of the API. Methods of manufacture are also disclosed.

Abstract: A method and apparatus for growing a crystalline or poly-crystalline body from a melt is described, wherein the melt is retained by capillary attachment to edge features of a mesa crucible. The boundary profile of the resulting melt surface results in an effect which induces a ribbon grown from the surface of the melt to grow as a flat body. Further, the size of the melt pool is substantially reduced by bringing these edges close to the ribbon, thereby reducing the materials cost and electric power cost associated with the process.

Abstract: A steel powder metal skeleton is infiltrated with an infiltrant composition similar to the skeleton, with an additional agent that depresses the melting point of the infiltrant relative to the skeleton. Infiltration is driven primarily by capillary pressure. The powder and infiltrant compositions differ primarily only in a higher concentration of a melting point depressant agent “MPD” in the infiltrant. Carbon (C) and silicon (Si) and several other elements can be elements in an MPD, either alone or in combination. Certain steel target compositions are such that a complementary infiltrant, and skeleton can be chosen such that a skeleton will remain solid at an infiltration temperature at which the infiltrant can be melted and fully infiltrated, and further where there is a persistent two phase field, with a liquid phase that is large enough (greater than 7% vol, and typically between 20 and 40 vol %) so that flow can be maintained without choke off from diffusional solidification.

Abstract: Processes for providing enhanced thermal properties of tooling, particularly metal and metal/ceramic molds, made by solid free form fabrication techniques, such as the three dimensional printing process, and the tooling made by these processes are disclosed. The methods of enhancing thermal properties include incorporating integral contour coolant channels into the mold, adding surface textures to the coolant channels, creating high thermal conductivity paths between the surfaces and the coolant channels, and creating low thermal inertia regions in the mold.

Abstract: A system for producing three dimensional components by bonding together successive layers of a porous material with droplets of a binder material. A binder printhead has an array of nozzles which controllably supply jets of binder material droplets to the layers of porous material. The printhead is scanned in a raster scan fashion over each layer of porous material along a first scan axis in one direction to provide first fast scanning paths of droplets. The printhead is then moved laterally of such one direction and is then moved along the fast-scan axis in the opposite direction to provide second fast scanning paths of droplets which are interlaced with the first scanning paths. The supply of the droplets to the porous material can be controlled so as to control the overlapping thereof to produce various desired surface and interior characteristics of the components.

Abstract: Processes for providing enhanced thermal properties of tooling, particularly metal and metal/ceramic molds, made by solid free form fabrication techniques, such as the three dimensional printing process, and the tooling made by these processes are disclosed. The methods of enhancing thermal properties include incorporating integral contour coolant channels into the mold, adding surface textures to the coolant channels, creating high thermal conductivity paths between the surfaces and the coolant channels, and creating low thermal inertia regions in the mold.

Abstract: A droplet generator and ink jet printhead assembly employing the droplet generator are disclosed. The droplet generator can operate with a wide range of fluids over a wide range of conditions, is easily serviced, and can be easily integrated into a machine such as a Three Dimensional Printing machine. The assembly includes a nozzle having an orifice, a liquid reservoir or supply for containing a liquid to be emitted from the nozzle and a non-resonant elastically deformable fluid conduit for conveying the liquid from the liquid reservoir to the nozzle. A transducer is disposed in abutting relation with the fluid conduit a predetermined distance from the nozzle. The transducer is energized by a suitable electrical signal, such as a sinusoidal signal. The transducer causes compression of the conduit and provides a wave which propagates along the fluid conduit and fluid contained therein toward the nozzle and orifice.

Abstract: A system for producing three dimensional components by bonding together successive layers of a porous material with droplets of a binder material. A binder printhead has an array of nozzles which controllably supply jets of binder material droplets to the layers of porous material. The printhead is scanned in a raster scan fashion over each layer of porous material along a first scan axis in one direction to provide first fast scanning paths of droplets. The printhead is then moved laterally of such one direction and is then moved along the fast-scan axis in the opposite direction to provide second fast scanning paths of droplets which are interlaced with the first scanning paths. The supply of the droplets to the porous material can be controlled so as to control the overlapping thereof to produce various desired surface and interior characteristics of the components.

Abstract: Processes for providing enhanced thermal properties of tooling, particularly metal and metal/ceramic molds, made by solid free form fabrication techniques, such as the three dimensional printing process, and the tooling made by these processes are disclosed. The methods of enhancing thermal properties include incorporating integral contour coolant channels into the mold, adding surface textures to the coolant channels, creating high thermal conductivity paths between the surfaces and the coolant channels, and creating low thermal inertia regions in the mold.

Abstract: The invention is a method for making a metal containing article, comprising the steps of: providing a layer of a porous ground in a selected area; exposing selected regions of the layer of porous ground to light, thereby metallizing the selected regions; repeating the foregoing steps a selected number of times to produce a selected number of layers; and selectively modifying the metallized regions of the layers. The initial metallization can be by electroless or semiconductor photo deposition plating. The subsequent modification of the metallized regions can be by electroless plating, electroplating or sintering. It is also possible, in some instances, to forego the second phase modification, the initial phase having provided the desired parameters. In a third preferred embodiment, the invention is a method using an initial metallization phase effected by exposure of a metal salt, such as a metal halide, to light, thereby inducing activation of the halide.

Abstract: A tactile computer input device which simulates an object being designed is used with a computer aided design (CAD) system. The input device allows a user to manually manipulate the input device as if it were the object under design. A preferred embodiment is directed toward the design of sheet metal parts. The design begins with a virtual metal sheet which is then manipulated by a user through manual manipulation of the input device. Bending of the virtual object is accomplished by bending of the input device. Stretching and shrinking of the virtual object is accomplished by expanding and compressing the input device. Spatial orientation of the virtual object follows the spatial orientation of the input device by providing the input device with a Polhemus orientation sensor. Other functions for manipulating the virtual sheet metal object include cutting, embossing, and punching.

Abstract: A process for making a component by depositing a first layer of a powder material in a confined region and then depositing a binder material to selected regions of the layer of powder material to produce a layer of bonded powder material at the selected regions. Such steps are repeated a selected number of times to produce successive layers of selected regions of bonded powder material so as to form the desired component. The unbonded powder material is then removed. In some cases the component may be further processed as, for example, by heating it to further strengthen the bonding thereof.