Abstract: Materials, designs, and methods of fabrication for electrodes for electrochemical cells are disclosed. In various embodiments, the electrode comprises iron. Various embodiments may include materials, systems, and methods for the use of various iron-bearing materials, starting from the discharged or partially discharged state in an alkaline electrochemical cell, such as an Fe—Ni, Fe—MnO2, or Fe-air battery. Various embodiments may include a battery comprising an electrode comprising iron. In various embodiments, the iron may be in various forms, such as iron ore, iron concentrate, iron pellets, BF grade pellets, DR grade pellets, hematite, magnetite, wustite, martite, goethite, limonite, siderite, pyrite, ilmenite, spinel manganese ferrite, etc. In various embodiments, the iron may include impurity phases, such as SiO2, CaO, etc.

Abstract: Various embodiments relate to several processes that may recover commodity chemicals from an alkaline metal-air battery. In various embodiments, while the cell is operating, various side products and waste streams may be collected and processed to regain use or additional value. Various embodiments also include processes to be performed after the cell has been disassembled, and each of its electrodes have been separated such as not to be an electrical hazard. The alkaline metal battery recycling processes described herein may provide multiple forms of commodity iron, high purity transition metal ores, fluoropolymer dispersions, various carbons, commodity chemicals, and catalyst dispersions.

Abstract: Devices, systems, and methods are directed to binder jetting for forming three-dimensional parts having controlled, macroscopically inhomogeneous material composition. In general, a binder may be delivered to each layer of a plurality of layers of a powder of inorganic particles. An active component may be introduced, in a spatially controlled distribution, to at least one of the plurality of layers such that the binder, the powder of inorganic particles, and the active component, in combination, form an object. The object may be thermally processed into a three-dimensional part having a gradient of one or more physicochemical properties of a material at least partially formed from thermally processing the inorganic particles and the active component of the object.

Abstract: Systems and methods of the various embodiments may provide porous materials for electrodes of electrochemical energy storage systems.

Abstract: A method for fabricating an infiltrated object of a desired shape having a high volume fraction of infiltrant using an additively manufactured preform. Using an additive manufacturing technique, the preform is formed with graded macro-porosity. When infiltrated, the void volume of the macro-porosity is filled with infiltrant Optionally, the void volume may be varied across the profile of the object to create a gradient of mechanical properties in the infiltrated object.

Abstract: Techniques and compositions are disclosed for three-dimensional printing with powder/binder systems including, but not limited to, metal injection molding powder materials, highly-filled polymer composites, and any other materials suitable for handling with various additive manufacturing techniques, and further suitable for subsequent debinding and thermal processing into a final object.

Abstract: Devices, systems, and methods are directed to the use of nanoparticles for improving strength fabrication of three-dimensional objects formed through layer-by-layer process in which an ink is delivery of a binder delivered onto successive layers of a powder of inorganic particles in a powder bed. More specifically, nanoparticles of inorganic material can may be introduced into one or more layers of the metal powder in the powder bed and thermally processed to facilitate sinter necking, in the powder bed, of the metal particles forming the three-dimensional object. Such sinter necking in the powder bed can may improve strength of the three-dimensional objects being fabricated and, also or instead, can may reduce the likelihood of defects associated with subsequent processing of the three-dimensional objects (e.g., slumping and shrinking in a final sintering stage and/or inadequate densification of the final part).

Abstract: A method for binder jetting a three-dimensional (3D) object includes receiving a geometry of the object to be printed and generating instructions for printing the object. Generating the instructions includes slicing the geometry of the object into a series of cross-sectional shapes corresponding to where a binder fluid will be deposited onto a powder bed to form the object, and including a plurality of negatively printed features within at least some of the series of cross-sectional shapes, wherein an amount of binder fluid to be deposited in the negatively printed features is less than an amount of binder fluid to be deposited in a remainder of the cross-sectional shape. The amount of binder fluid to be deposited in the negatively printed features and a size of the negatively printed features is configured to allow gas to escape from the powder bed.

Abstract: Systems, methods, components, and materials are disclosed for stereolithographic fabrication of three-dimensional, dense objects. A resin including at least one component of a binder system and dispersed particles can be exposed to an activation light source. The activation light source can cure the at least one component of the binder system to form a green object, which can include the at least one component of the binder system and the particles. A dense object can be formed from the green object by removing the at least one component of the binder system in an extraction process and thermally processing particles to coalesce into the dense object.

Abstract: Disclosed is a method and material system for fabricating metal infiltrated objects having a high volume fraction of infiltrant relative to the infiltrated preform. In an embodiment method, a composite is formed into the shape of a desired object, the composite including a skeletal phase and a fugitive phase. The fugitive phase is then removed to create a self-supporting porous skeletal structure. The porous skeletal structure is then infiltrated with the infiltrant to achieve a densified object.

Abstract: A method of maintaining part geometry fidelity during infiltration of a metallic preform. The preform and an infiltration barrier are formed, either independently or together during an additive manufacturing process. The infiltration barrier prevents infiltrant from bleeding out from the preform where it is present, thus protecting fine geometries that would otherwise be filled with infiltrant.

Abstract: Materials, designs, and methods of fabrication for iron-manganese oxide electrochemical cells are disclosed. In various embodiments, the negative electrode is comprised of pelletized, briquetted, or pressed iron-bearing components, including metallic iron or iron-based compounds (oxides, hydroxides, sulfides, or combinations thereof), collectively called “iron negative electrode.” In various embodiments, the positive electrode is comprised of pelletized, briquetted, or pressed manganese-bearing components, including manganese (IV) oxide (MnO2), manganese (III) oxide (Mn2O3), manganese (III) oxyhydroxide (MnOOH), manganese (II) oxide (MnO), manganese (II) hydroxide (Mn(OH)2), or combinations thereof, collectively called “manganese oxide positive electrode.” In various embodiments, electrolyte is comprised of aqueous alkali metal hydroxide including lithium hydroxide (LiOH), sodium hydroxide (NaOH), potassium hydroxide (KOH), cesium hydroxide (CsOH), or combinations thereof.

Abstract: Systems and methods of the various embodiments may provide low cost bifunctional air electrodes. Various embodiments may provide a bifunctional air electrode, including a metal substrate and particles of metal and/or metal oxide catalyst and/or metal nitride catalyst coated on the metal substrate. Various embodiments may provide a bifunctional air electrode, including a first portion configured to engage an oxygen reduction reaction (ORR) in a discharge mode and a second portion configured to engage an oxygen evolution reaction (OER) in a charge mode. Various embodiments may provide a method for making an air electrode including coating a metal substrate with particles of metal and/or metal oxide catalyst and/or metal nitride catalyst. Various embodiments may provide batteries including air electrodes.

Abstract: Devices, systems, and methods are directed to applying magnetohydrodynamic forces to liquid metal to eject liquid metal along a controlled pattern, such as a controlled three-dimensional pattern as part of additive manufacturing of an object. Porosity of one or more predetermined portions of objects fabricated from an accumulation of liquid metal droplets ejected using magnetohydrodynamic force can be controlled to form interfaces between support structures and parts within the object. Higher porosity along the interfaces, as compared to porosity along the support structures and the parts, can be useful for facilitating separation of the parts from the support structures.

Abstract: Materials and methods are disclosed for forming interface layers between objects being 3D printed and their underlying support structures, as well as dissolvable supports. The materials and methods facilitate separation of the objects from the supports after all processing is completed and are particularly useful when 3D printing metal objects that have to be sintered subsequent to 3D printing.

Abstract: An additive manufacturing method including depositing a first amount of metal powder on a print bed, the first amount metal powder forming a first layer, depositing a first binder component to the first layer in a first region, and depositing a second binder component to the first layer in a second region.

Abstract: The present invention relates to a shrinking interface composition that allows for the accommodation of sintering shrinkage between two or more areas or sections of a three-dimensionally printed part and/or support structures for the part. The interface composition, which can be in the form of an interface layer, is used to prevent the fusing of the sections, parts or support structures to each other.

Abstract: A variety of additive manufacturing techniques can be adapted to fabricate a substantially net shape object from a computerized model using materials that can be debound and sintered into a fully dense metallic part or the like. However, during sintering, the net shape will shrink as binder escapes and the base material fuses into a dense final part. If the foundation beneath the object does not shrink in a corresponding fashion, the resulting stresses throughout the object can lead to fracturing, warping or other physical damage to the object resulting in a failed fabrication. To address this issue, a variety of techniques are disclosed for substrates and build plates that contract in a manner complementary to the object during debinding and sintering.

Abstract: A three-dimensional printer includes a vessel containing a liquid in which a printed object can debind during fabrication. More generally, the vessel may contain any liquid medium selected to control or modify properties of a printed object during fabrication. For example, the liquid may also or instead impose a controlled thermal environment for the printed object, apply finishing materials to an exterior surface of the object, provide a component or catalyst for a reaction, or otherwise treat the printed object or control ambient conditions during printing.

Abstract: Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is fabricated between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering. Interface layers suitable for manufacture with an additive manufacturing system may resist the formation of bonds between a support structure and an object during subsequent sintering processes.