Abstract: A method of making a metallic component includes mounting a polymeric scaffold onto a mandrel, wherein the mandrel includes one or more chucks configured to secure the polymeric scaffold onto the mandrel and wherein the mandrel is configured to rotate the polymeric scaffold; depositing, with a second additive manufacturing (AM) technique using a material applicator, a component material onto the polymeric scaffold to form the metallic component on the polymeric scaffold, wherein the component has a shape that is the same as the polymeric scaffold; removing the polymeric scaffold; and the metallic component deposited on the polymeric scaffold from the mandrel; and removing the polymeric scaffold from the metallic component.

Abstract: A build piston for a powder bed fusion (PBF) additive manufacturing system is an annular build platform that includes a drive shaft, bearing sleeve, and drive shaft actuation mechanism. The end of the drive shaft is attached to the bottom center of the build platform and moves the build platform in concert with the drive shaft. The bearing sleeve ensures linear alignment of the drive shaft. The drive shaft actuation mechanism rotates the drive shaft at a continuous rate that is coupled to the drive shaft's rate of translation up and down, moving the build platform in a helical pattern.

Abstract: A build plate for a powder bed fusion (PBF) additive manufacturing system is an annular build plate that includes an inner radius wall and an outer radius wall that each extend vertically from a junction with the annular build plate to define a build area on the annular build plate. The inner radius wall and the outer radius wall each include a plurality of apertures that are configured to collect excess build powder and direct the excess build powder through the inner radius wall and outer radius wall to an excess build powder reservoir. The annular build plate is configured to be positioned on a build piston and to move in concert with the build piston, wherein the build piston is configured to rotate around a drive shaft in a continuous circular motion and to translate up and down with respect to the annular build plate.

Abstract: A powder bed fusion (PBF) additive manufacturing system includes an annular build plate including an inner radius wall and an outer radius wall, wherein the inner radius wall and the outer radius wall define a build area on the annular build plate between the inner radius wall and the outer radius wall. A build piston is configured to rotate around a drive shaft in a continuous circular motion and to translate up and down with respect to the annular build plate, wherein the annular build plate is configured to be positioned on the build piston and to move in concert with the build piston. A build powder delivery mechanism is configured to deliver build powder to the build area to form a build powder bed when the PBF additive manufacturing system is in operation. A recoater is configured to provide even distribution of the build powder in the build powder bed when the PBF additive manufacturing system is in operation.

Abstract: A powder bed fusion (PBF) additive manufacturing system includes a powder delivery mechanism configured to deliver build powder to a build area of an annular build plate to form a build powder bed while the annular build plate rotates when the PBF additive manufacturing system is in operation and a recoater configured to provide a uniform density of power packing of the build powder in the build powder bed while the annular build plate rotates when the PBF additive manufacturing system is in operation. The recoater has at least one segment positioned at an acute angle relative to an axis perpendicular to a direction of rotation of the annular build plate.

Abstract: An annular part made with a powder bed fusion (PBF) additive manufacturing system includes a continuous, single layer of sintered and consolidated build powder that is helically overlapped on itself across an entire thickness of the part. The part has an annular cross section defined by an inner radius and an outer radius and the circumference defined by the inner radius defines an outer radius of an annulus of the part. The part can be made by installing in the PBF additive manufacturing system an annular build plate including an inner radius wall and an outer radius wall that define a build area on the annular build plate. Build powder is delivered to the build area with a powder delivery mechanism to form a build powder bed while a recoater distributes the build powder to provide even distribution of the build powder in the build powder bed. An optical array positioned over the build area directs energy onto the build powder to form a melt pool.

Abstract: A build head for a powder bed fusion (PBF) additive manufacturing system includes a powder delivery mechanism configured to deliver build powder to a build area of an annular build plate to form a build powder bed while the annular build plate rotates when the PBF additive manufacturing system is in operation. A recoater is configured to provide even distribution of the build powder in the build powder bed and an optical array is positioned over the build area on the build plate to project energy onto the build powder bed to form a melt pool in the build powder bed.

Abstract: A annular build plate for a powder bed fusion (PBF) additive manufacturing system includes an inner radius wall and an outer radius wall. The inner radius wall and the outer radius wall define a build area on the annular build plate between the inner radius wall and the outer radius wall. The annular build plate is configured to be positioned on a build piston and to move in concert with the build piston, which is configured rotate around a drive shaft in a continuous circular motion and to translate up and down with respect to the annular build plate. A method of making an annular part with a PBF additive manufacturing system includes installing in the PBF additive manufacturing system an annular build plate having an inner radius wall and an outer radius wall. Build powder is delivered, with a powder delivery mechanism, to the build area to form a build powder bed and the build powder in the build powder bed is distributed, with a recoater, to provide even distribution of the build powder.

Abstract: An expandable wheel (100) assembly attached to a vehicle includes a circular rim disc (200) operable to receive a plurality of drive members (300) about its circumference. The drive members (300) are pivotally connected to the rim disc (200) and expand outward from the rim disc (200) via sliding levers (500) when a rotational force is applied to the rim disc (200). As a result, the drive members (300) increase the ground clearance and enhance the ability for the vehicle to negotiate variable terrain while also increasing the top velocity of the vehicle. The expandable wheel (100) assembly contracts to a circumferential closed position when the rotational force is removed.

Abstract: An expandable wheel (100) assembly attached to a vehicle includes a circular rim disc (200) operable to receive a plurality of drive members (300) about its circumference. The drive members (300) are pivotally connected to the rim disc (200) and expand outward from the rim disc (200) via sliding levers (500) when a rotational force is applied to the rim disc (200). As a result, the drive members (300) increase the ground clearance and enhance the ability for the vehicle to negotiate variable terrain while also increasing the top velocity of the vehicle. The expandable wheel (100) assembly contracts to a circumferential closed position when the rotational force is removed.

Abstract: A template for evaluating a part, comprising: a surface having a shape corresponding to the part; and at least one element on the surface corresponding to a desired location of a feature on the part. A method of evaluating a part, comprising the steps of: providing a template having a shape corresponding to the part and at least one element thereon corresponding to a desired location on the part; associating the template with the part; and using the element to determine whether the feature is at the desired location.