Abstract: The invention relates to a device and method for preparing a structure or object using an additive manufacturing process referred to as sequential cold spray laser sintering. The method includes depositing by cold spraying a plurality of sequential layers of material onto a substrate/build plate or particles of materials onto a compacted powder bed of material and employing an energy source to sinter or melt each of the plurality of sequential layers or powders to produce sequential sintered layers, wherein the number of additional layers is determined based on those needed to produce the final structure.

Abstract: The current invention includes an additive manufactured electrode that may be used for a flow battery system. In some embodiments, the electrode may include a composite material and/or at least one flow channel to direct, or at least influence, flow of electrolyte. The flow channel can be formed onto a surface and/or within a body of the electrode, and may be used to generate fluid pathways that cause the electrolyte to flow in a certain manner. The composite material may include a rigid core and a flexible compressible outer layer that may improve reactions zones, enhance mechanical properties, and/or provide low-pressure paths for electrolyte to flow.

Abstract: The current invention includes an additive manufactured electrode that may be used for a flow battery system. In some embodiments, the electrode may include a composite material and/or at least one flow channel to direct, or at least influence, flow of electrolyte. The flow channel can be formed onto a surface and/or within a body of the electrode, and may be used to generate fluid pathways that cause the electrolyte to flow in a certain manner. The composite material may include a rigid core and a flexible compressible outer layer that may improve reactions zones, enhance mechanical properties, and/or provide low-pressure paths for electrolyte to flow.

Abstract: A method of producing a 3-dimensional (“3-D”) product from metals in the gaseous state includes the steps of providing a substrate of 3-D shape; providing a flow of a gaseous chemical compound(s) around the 3-D substrate, wherein the gaseous chemical compound(s) comprises a metal carbonyl gas; selectively heating the 3-D substrate to decompose the metal carbonyl gasses, wherein metal separated as a result of the decomposition is deposited on the 3-D substrate; selectively controlling the flow rate of one or more metal carbonyl gasses and the temporal and spatial temperature distribution throughout the 3-D substrate to achieve a desired thickness distribution of the metal or metals on the 3-D substrate; and removing the 3-D substrate to produce a resulting 3-D metal product with an complex geometry.