Abstract: Multifunctional structures and methods of manufacturing multifunctional structures which function as both electronic devices and load-bearing elements are disclosed. The load-bearing elements are designed to have electronic functionality using electronics designed to be load-bearing. The method of manufacturing the multifunctional structure comprises forming an electronic element directly on at least one ply of arbitrarily shaped load-bearing material using conventional lithographic techniques and/or direct write fabrication techniques, and assembling at least two plies of arbitrarily shaped load-bearing material into a multifunctional structure. The multifunctional structure may be part of an aerospace structure, part of a land vehicle, part of a watercraft or part of a spacecraft.

Abstract: Disclosed are reinforced metal matrix composites and methods of shaping powder materials to form such composites. Articles of manufacture are formed in layers by a laser fabrication process. In the process, powder is melted and cooled to form successive layers of a discontinuously reinforced metal matrix. The matrix exhibits fine grain structure with enhanced properties over the unreinforced metal, including higher tensile modulus, higher strength, and greater hardness. In some preferred embodiments, an in-situ alloy powder, a powder metallurgy blend, or independently provided powders are reinforced with boron and/or carbon to form the composite.

Abstract: Multifunctional structures and methods of manufacturing multifunctional structures which function as both electronic devices and load-bearing elements are disclosed. The load-bearing elements are designed to have electronic functionality using electronics designed to be load-bearing. The method of manufacturing the multifunctional structure comprises forming an electronic element directly on at least one ply of arbitrarily shaped load-bearing material using conventional lithographic techniques and/or direct write fabrication techniques, and assembling at least two plies of arbitrarily shaped load-bearing material into a multifunctional structure. The multifunctional structure may be part of an aerospace structure, part of a land vehicle, pan of a watercraft or part of a spacecraft.

Abstract: Disclosed are reinforced metal matrix composites and methods of shaping powder materials to form such composites. Articles of manufacture are formed in layers by a laser fabrication process. In the process, powder is melted and cooled to form successive layers of a discontinuously reinforced metal matrix. The matrix exhibits fine grain structure with enhanced properties over the unreinforced metal, including higher tensile modulus, higher strength, and greater hardness. In some preferred embodiments, an in-situ alloy powder, a powder metallurgy blend, or independently provided powders are reinforced with boron and/or carbon to form the composite.

Abstract: A method of fabricating ceramic parts is disclosed using a laser deposition process to produce highly dense ceramic parts. A metal substrate is preferably used and ceramic powder deposited in layers on the substrate, while varying the power of the laser beam to bond the layers together without cracking the substrate or causing a plasma reaction in the ceramic powder. Dense structures which are about 96% to about 100% ceramic can be produced. A part can be graded using different types and mixtures of ceramic powders to produce the part of a desired composition.