Abstract: A gear for transmitting motion and torque between components includes a first gear portion having a first material and which is formed by a first additive manufacturing process. The gear also includes a second gear portion having a second material and which is formed on the first gear portion. The second gear portion is formed by a second additive manufacturing process that is different from the first additive manufacturing process. At least one of the first gear portion or the second gear portion defines a plurality of teeth.

Abstract: The present disclosure is directed, in certain embodiments, a component of a mechanical apparatus. The component includes a cast body with an initial structure formed by a mold and at least one feature deposited on the cast body using a solid state additive manufacturing process, such that in combination the initial structure and the at least one feature form a complete structure of the component.

Abstract: The present disclosure is directed, in certain embodiments, a component of a mechanical apparatus. The component includes a cast body with an initial structure formed by a mold and at least one feature deposited on the cast body using a solid state additive manufacturing process, such that in combination the initial structure and the at least one feature form a complete structure of the component.

Abstract: The present disclosure is directed, in certain embodiments, a component of a mechanical apparatus. The component includes a cast body with an initial structure formed by a mold and at least one feature deposited on the cast body using a solid state additive manufacturing process, such that in combination the initial structure and the at least one feature form a complete structure of the component.

Abstract: An on-demand system for manufacturing service tools is provided. The system includes a digital manual including instructions for service/repair configured to be accessible by a computing device and a library containing one or more additive manufacturing files configured to be accessible by the computing device. An additive manufacturing printer is provided in communication with the computing device and configured to receive instructions therefrom based on the one or more additive manufacturing files. The system also includes a recycling device configured to recycle materials of items created by the additive manufacturing printer. The digital manual includes one or more links to the one or more additive manufacturing files of the library.

Abstract: A cast component includes a cast structure having a primary geometry formed by a mold. Also included is a structural deposit formed by cold spraying one or more layers of powdered material on an outer surface of the cast structure, the structural deposit defining at least one feature of the overall outer geometry of the cast component in addition to the primary geometry. Also provided are methods of manufacturing the cast component.

Abstract: A helicopter is provided and includes an engine, a rotor, a gear train configured to transmit torque from the engine to the rotor such that the rotor is rotatable about an axis of rotation, a primary lubrication system, which is configured to supply the gear train with a fluid and a secondary lubrication system disposed in a gear of the gear train, including a fluid reservoir, which is configured to receive and store the fluid and to continue to supply the gear train with the fluid following a failure of the primary lubrication system.

Abstract: A helicopter is provided and includes an engine, a rotor, a gear train configured to transmit torque from the engine to the rotor such that the rotor is rotatable about an axis of rotation, a primary lubrication system, which is configured to supply the gear train with a fluid and a secondary lubrication system disposed in a gear of the gear train, including a fluid reservoir, which is configured to receive and store the fluid and to continue to supply the gear train with the fluid following a failure of the primary lubrication system.

Abstract: A method of operating a machining system includes comparing one or more features of a cutting tool to information stored on a data chip secured to a tool holder of the cutting tool. The cutting tool is loaded into the machining system, and the information stored on the data chip is compared to cutting tool requirements of a machining program for instructing operation of the machine. When a result of one or more of the comparisons is outside of a predetermined threshold, operation of the machining system is stopped.

Abstract: A method of operating a machining system includes comparing one or more features of a cutting tool to information stored on a data chip secured to a tool holder of the cutting tool. The cutting tool is loaded into the machining system, and the information stored on the data chip is compared to cutting tool requirements of a machining program for instructing operation of the machine. When a result of one or more of the comparisons is outside of a predetermined threshold, operation of the machining system is stopped.