Abstract: Apparatus and a method for forming a metallic component by additive layer manufacturing are provided. The method includes the steps of using a heat source such as a laser to melt the surface of a work piece and form a weld pool; adding wire or powdered metallic material to the weld pool and moving the heat source relative to the work piece so as to progressively form a new layer of metallic material on the work piece; applying forced cooling to the formed layer; stress relieving the cooled layer by applying a peening step, for example with a pulsed laser, and repeating the above steps as required to form the component layer by layer.

Abstract: A structure to be monitored for damage and a method of monitoring the structure for damage are provided. The structure has a coating thereon, the coating defining a surface having characteristics which vary in a predetermined manner with damage to the structure. The surface has a series of conductive tracks applied thereto and in intimate contact therewith such that the said predetermined variation of the surface characteristics will vary the resistance of the series of conductive tracks in a predetermined manner in order to determine both location and extent of damage.

Abstract: A structure to be monitored for damage and a method of monitoring the structure for damage are provided. The structure has a coating thereon, the coating defining a surface having characteristics which vary in a predetermined manner with damage to the structure. The surface has a series of conductive tracks applied thereto and in intimate contact therewith such that the said predetermined variation of the surface characteristics will vary the resistance of the series of conductive tracks in a predetermined manner in order to determine both location and extent of damage.

Abstract: A method and apparatus for forming an object by additive layer manufacturing. The method comprises: a) applying, by a heat source (4), heat to a portion of a surface of a workpiece (1) sufficient to melt said portion; b) adding material to the melted portion and moving the heat source (4) relative to the workpiece (1) whereby progressively to form a layer of material (10) on the workpiece (1); c) cooling the formed layer (10) to bring at least part of the layer (10) to a state of crystallisation, there producing a modified workpiece; d) peening, using a plurality of independently controllable impact treatment devices (7), the modified work-piece so as to plastically deform the cooled at least part of the layer (10); and repeating steps a) to d) as required whereby to form the object.

Abstract: Apparatus and a method of forming a composite component (8) by additive layer manufacturing are provided. The method includes the steps of providing an elongate tape (2) of carbon nanotubes (CNTs), applying stretching force to the tape (2) whereby to align the carbon nanotubes to the tape and form an aligned tape (27), impregnating the tape (27) with matrix material (40, 48, 50), forming the aligned tape (27) into portions (43) of required size and transferring the portions as required to a component build location whereby to form the component (8), layer by layer.

Abstract: Apparatus and a method for forming a metallic component by additive layer manufacturing are provided.

Abstract: A selective layer melting or other additive layer fabrication method in which powdered material is fused by heating it with a pulsed laser, the pulses being modulated while the laser is traversing the substrate so as to control the thickness and/or width of the layer being formed. Initial layers of the fabrication structure may be formed more thickly than subsequent layers, e.g. by means of a CW laser, to reduce distortion. This aspect of the invention may be employed independently of the use of a pulsed laser to form the subsequent layers.

Abstract: Apparatus and a method for forming a metallic component by additive layer manufacturing are provided.

Abstract: A method and apparatus are disclosed for the formation of optical fiber structures. An exemplary fiber laying head houses a source of optical fiber material to which an adhesive coating is applied prior to laying the adhesive-coated optical fiber material onto a substrate. The fiber laying head can also house a radiation source that generates a radiation beam to cure the adhesive in the adhesive-coated optical fiber material to form a bond between the adhesive-coated optical fiber material and the substrate.

Abstract: Apparatus and a method for forming a metallic component by additive layer manufacturing are provided. The method includes the steps of using a heat source such as a laser to melt the surface of a work piece and form a weld pool; adding wire or powdered metallic material to the weld pool and moving the heat source relative to the work piece so as to progressively form a new layer of metallic material on the work piece; applying forced cooling to the formed layer; stress relieving the cooled layer by applying a peening step, for example with a pulsed laser, and repeating the above steps as required to form the component layer by layer.

Abstract: Apparatus and a method of forming a structure (304) are disclosed. The method includes applying a heat treatment to a first area (206) on a first surface (201A) of a work piece (200), wherein at least one dimension of the first area corresponds to a maximum design dimension of a structure (304) to be formed. The structure is then formed on a second area (303) on an opposite surface (201B) of the work piece, the second area having a location corresponding to the first area.

Abstract: An additive layer manufacturing system and method are provided. The system includes a powder delivery system providing at least one powder feed from a powder stock to a powder exit adjacent a deposition point. The powder delivery system further comprises at least one valve system proximal to the powder exit for controlling the flow of the at least one powder feed at the deposition point.

Abstract: A method of fabricating structural elements on the surface of a component is provided. The structural elements are configured to modify flow of a fluid passing over the surface. Conveniently, the fabrication is performed using a Direct Write technique. A three dimensional element is formed by depositing material on the surface, and subsequently curing the deposited material.

Abstract: Described herein is a method and apparatus for the formation of optical fibre structures. A fibre laying head (200) houses a source of optical fibre material (204) to which an adhesive coating is applied prior to laying the adhesive-coated optical fibre material onto a substrate (214). The fibre laying head (200) also houses a radiation source (212) that generates a radiation beam (216) to cure the adhesive in the adhesive-coated optical fibre material to form a bond between the adhesive-coated optical fibre material and the substrate.

Abstract: A selective layer melting or other additive layer fabrication method in which powdered material is fused by heating it with a pulsed laser, the pulses being modulated whilst the laser is traversing the substrate so as to control the thickness and/or width of the layer being formed. Initial layers of the fabrication structure may be formed more thickly than subsequent layers, e.g. by means of a CW laser, to reduce distortion. This aspect of the invention may be employed independently of the use of a pulsed laser to form the subsequent layers.

Abstract: A selective layer melting or other additive layer fabrication method in which powdered material is fused by heating it with a pulsed laser, the pulses being modulated whilst the laser is traversing the substrate so as to control the thickness and/or width of the layer being formed. Initial layers of the fabrication structure may be formed more thickly than subsequent layers, e.g. by means of a CW laser, to reduce distortion. This aspect of the invention may be employed independently of the use of a pulsed laser to form the subsequent layers.

Abstract: A Direct Write method of forming components on a substrate by deposition of ink by thermally curing the ink in situ, which method overcomes the need for curing by placing the substrate in an oven. The curing is performed in an exemplary embodiment using an induction coil (6) through which an oscillating current is passed. The coil (6) is placed above the region in which Direct Write ink has been deposited. The oscillating current induces eddy currents in the ink to cause heating of the ink and thus fix the ink by curing, sintering etc.

Abstract: A method of fabricating an object is disclosed. A first layer of powder is deposited onto a substrate in a configuration defining a first cross-section of the object, and is consolidated by laser irradiation. To fabricate the object, further layers of powder are deposited onto the sintered first layer of powder to define further cross-sections of the object. The further layers are consolidated. A heat source is applied to the substrate to mitigate distortion of the substrate during fabrication of the object.

Abstract: A damage sensing system, and a method of sensing damage using the system, are described. The system comprises: a plurality of tuned circuits arranged in parallel, each tuned circuit having a different resonant frequency; and processing means for discriminating the response of the different tuned circuits according to their respective different resonant frequencies, for example by processing changes in the respective Q-factors of the respective tuned circuits; wherein each of the plurality of tuned circuits comprises a respective damage sensor, each damage sensor comprising at least one direct write resistive element applied to an area of a substrate by a direct write process. Each tuned circuit may comprise a common resistor in series with the respective damage sensor. The plurality of the tuned circuits may be coupled to the processing means by a shared single pair of external connections.

Abstract: A damage sensor, for example a crack gauge, a method of providing the same, and a method of sensing damage using the same, are described. The damage sensor comprises at least one direct write resistive element applied to an area of a substrate by a direct write process. Conductive tracks may be connected along two separated portions of the perimeter of the area of the direct write resistive element. The damage sensor may comprise plural direct write resistive elements, for example rectangular-shaped elements, each extending between and connected to two conducting tracks. In a further damage sensor, plural annular resistive elements are positioned in an annular arrangement with respect to each other. In all the damage sensors, the resistive elements may be applied around a hole in a substrate, or extending over a bonded edge between two substrates.