Abstract: A shock absorber includes a three-dimensional structure composed of a unit structure repeatedly, regularly and continuously arranged in at least one direction, the unit structure being a three-dimensional shape formed by a wall having an external shape defined by a pair of parallel planes or curved surfaces. When the unit structure occupies a cuboidal space representing a unit space and defined by mutually orthogonal three sides having a first side extending in an axial direction in which the shock absorber exhibits a shock absorbing function as the shock absorber receives a load and second and third sides each extending from one end of the first side in a direction orthogonal to the axial direction, and the first side has a length L1 and a longer one of the second and third sides has a length L2, the shock absorber satisfies 1.1?L1/L2?4.0.

Abstract: The present disclosure provides a composite structure, including first and second structure layers which are opposite to each other and adjustment bodies. The first structure layer includes first structure bodies. The second structure layer includes second structure bodies. The first structure bodies and the second structure bodies are staggered. First connecting portions protruding toward the second structure layer are provided at predetermined positions on the first structure bodies where the first structure bodies are staggered relative to the second structure bodies, and second connecting portions protruding toward the first structure layer are provided at predetermined positions on the second structure bodies where the second structure bodies are staggered relative to the first structure bodies, and the first connecting portions and the second connection portions are staggered.

Abstract: Implantable drug-eluting device (1) comprising a microporous structure (2) having regularly arranged pores (4, 5) in at least two different uniform sizes, and manufacturing method. The pores are configured for receiving a drug (9) and are being connected by interconnections (6, 7). Interconnections (6) originating from pores (4) of a first size have a first elution area and interconnections (7) originating from pores (5) of a second size have a second elution area. The interconnections convey the drug (9) to a surface of the device for elution to surrounding tissue. The ratio between the first and the second elution areas is predefined and selectable. The differently sized elution areas provide for different outflow rates. This allows for simple but reliable dispensing of drugs at positively controlled and well determined rates. Particularly, this enables a single implantable device to dispense drugs over preselectable durations of time, like short-term or long-term.

Abstract: A composite plate structure includes a composite plate and a resin component. The composite plate includes a first fiber layer, a second fiber layer and a core layer. The second fiber layer has a first region, wherein an area of the second fiber layer is smaller than an area of the first fiber layer. The core layer is disposed between the first fiber layer and the second fiber layer, wherein the core layer is exposed at the first region. The resin component is connected to the composite plate, wherein the resin component is combined with the core layer at the first region. In addition, a manufacturing method of the composite plate is also provided.

Abstract: An information handling system housing provides a reduced overall material thickness by forming a planar housing piece of a first metal, such as aluminum, with an interior surface having channels of reduced thickness and laser sintering a pattern in the channel with a second material, such as a pattern of interconnected hexagons formed by lines of steel. Locally formed shapes of components disposed in the housing, such as battery shape, provide room for the components with improved stiffness of the housing to meet structural constraints.

Abstract: Trickle bodies for the air conditioning of, in particular, animal housings, that possess only partially latticed layer elements. Trickle bodies are formed of a plurality of sandwiched layer elements that, in known trickle bodies, are formed of corrugated and completely latticed plastics foil. The trickle bodies formed of such layer elements possess a relatively low stability and a limited evaporation capacity. The plastics-formed layer elements of the instant invention are produced by injection molding, allowing layer elements having corrugation heights of more than 12 mm to be formed. Such trickle bodies are more stable, enable a high evaporation capacity and are, moreover, also less permeable to light.

Abstract: A vehicle floor panel is provided in which a honeycomb core made of metal sandwiched and adhered between two CFRP plates is one in which a large number of core units formed into a polygon shape are continuous within one plane so as to share a side of the polygon. Since closed-section parts formed by a hat-shaped cross section part formed along the side and one CFRP plate are continuous with each other at a vertex of the polygon of the adjacent core units, not only is it possible to lighten the weight by opening the interior of the polygon (P) shape core unit, but it is also possible to enhance the energy-absorbing performance by dispersing and transmitting a collision load inputted into one direction of the floor panel toward a plurality of other directions because the high strength load transmission path is continuous with other load transmission paths.

Abstract: An interbody implant can comprise a cage and a porous structure. The cage can comprise an anterior segment, a medial segment, a posterior segment and a lateral segment contiguously connected to each other to define an interior space. The porous structure can be located in the interior space and can be bounded by the cage. The porous structure can comprise opposed superior and inferior surfaces exposed through the cage, an internal cavity located in an interior of the porous structure, and a plurality of ports connecting the internal cavity to the superior and inferior surfaces. A superior-inferior stiffness of the interbody implant can be defined by the porous structure. The porous structure can be compressed within a patient by movement of the spine to biologically stimulate bone growth in vertebrae adjacent the interbody implant. The implant can be configured for lateral, anterior and posterior insertion at different spine levels.

Abstract: A display device includes a liquid crystal display module, a cover lens, and a polarizer structure. The liquid crystal display module has a display area and a non-display area connected to the display area. The liquid crystal display module includes a bezel, a backlight module, and a display panel. The display panel includes a first substrate, a lower polarizer, a second substrate, a liquid crystal layer, and a filter element. The polarizer structure is located between the cover lens and the second substrate. The polarizer structure includes a plurality of grids and a reflective layer. The grids cover the display area. The reflective layer surrounds the grids and covers a sidewall of the display panel and a sidewall of the bezel in a direction perpendicular to the cover lens. A manufacturing method of the polarizer structure is also provided.

Abstract: A lightweight transportable containerized shelter includes wall panels made of a non-metal composite material coated at least on its inner face with a metal layer for EMI protection. The several wall panels are secured to a metal structural frame without the use of fasteners so as to define a containerized transportable shelter. The shelter meets ISO standards 668 and 1496. The shelter provides a continuous barrier to electromagnetic signals. Moreover, the containerized shelter is amenable to nine high stacking as required for ISO certification.

Abstract: An adsorptive cooling system includes: a first highly adsorptive structure positioned to receive thermal energy from a thermal energy source, the first highly adsorptive structure including: a first substrate; and a first carbon aerogel adhered to the first substrate, a second highly adsorptive structure positioned to receive thermal energy from the thermal energy source, the second highly adsorptive structure including: a second substrate; and a second carbon aerogel adhered to the second substrate, a cooling unit; and a circulation system adapted for circulating the refrigerant from at least one of the first highly adsorptive structure and the second highly adsorptive structure to the cooling unit to provide cooling from the thermal energy source and to return the refrigerant from the cooling unit to at least one of the first highly adsorptive structure and the second highly adsorptive structure.

Abstract: A metallic honeycomb body with channels through which a gas may flow, made up of layers of at least partially structured sheet metal, the layers of sheet metal having at least in subregions at least two different structures, of which the first structure, with a greater structure height (H), determines the size of the channels and the second structure has a much smaller structure height (h) between troughs and peaks and the form and/or the structure height (H) of the second structure being chosen such that a ceramic coating applied later may fill the troughs of the second structure on average to at least 10%, in particular at least 50%, of their structure height (h). With the honeycomb body according to the invention, more coating material per unit of volume is durably attached in a metallic honeycomb body without excessively increasing the pressure loss. This is of advantage particularly for applications for reducing nitrogen oxides (NOx) in diesel exhaust gases.

Abstract: A highly adsorptive structure includes: a substrate; and a carbon aerogel adhered to the substrate, wherein the carbon aerogel is characterized by having physical characteristics of in-situ formation on the substrate, and wherein the carbon aerogel is configured to selectively adsorb and desorb one or more refrigerants selected from the group consisting of: acid halides, alcohols, aldehydes, amines, chlorofluorocarbons, esters, ethers, fluorocarbons, perfluorocarbons, halocarbons, halogenated aldehydes, halogenated amines, halogenated hydrocarbons, halomethanes, hydrocarbons, hydrochlorofluorocarbons, hydrofluoroethers, hydrofluoroolefins, inorganic gases, ketones, nitrocarbon compounds, noble gases, organochlorine compounds, organofluorine compounds, organophosphorous compounds, organosilicon compounds, oxide gases, refrigerant blends and thiols.

Abstract: Beaded panels and method of forming beaded panels. A beaded panel as described herein includes a base structure comprising a sheet of material, and beads that comprise a protrusion on a first side of the base structure, and a concavity on an opposing second side of the base structure. A geometry of the beads comprises a center section having a conic shape about a longitudinal axis, flared sections symmetric about the center section along the longitudinal axis, and a transition section that curves outward from a base of the center section and the flared sections to blend with a flat surface on the first side of the base structure.

Abstract: A light-weight, high-strength compressor component is formed via additive manufacturing that has controlled stiffness and/or deflection levels. The component may have at least one interior region comprising a lattice structure that comprises a plurality of repeating cells. A solid surface is disposed over the lattice structure. The interior region comprises the lattice structure in the body portion of the light-weight, high-strength compressor component. The lattice structure may be used to globally or locally control stiffness and/or deflection levels of the compressor component. Additive manufacturing provides flexibility in forming compressor components with desirably improved strength-to-weight ratios while exhibiting high levels of control over stiffness and/or deflection. Methods of making such compressor components via additive manufacturing processes are also provided.

Abstract: The heat insulation coating includes the particles (secondary particles) of the silica aerogel (i) and the silica-based binder (ii). The thickness of the heat insulation coating is several 10 to several 100 ?m. The particle size of the secondary particles is distributed in a range from the lower limit Rmin to the upper limit Rmax. The lower limit Rmin is 10 nm. The upper limit Rmax is equal to the coating thickness of the heat insulation coating.

Abstract: Disclosed herein is a biomaterial for treating a condition. A biomaterial of the disclosure can be, for example, a surgical article. The biomaterial can comprise a plurality of geometric elements and a therapeutic agent. The biomaterial can comprise a first geometric element formed by a porous border that comprises a polymer and the therapeutic agent. The biomaterial can comprise a second geometric element formed by a non-porous border and a solid region, wherein the therapeutic agent may not diffuse into the second geometric element. Implantation of a biomaterial disclosed herein into a subject can treat, for example, cancer.

Abstract: A method for vacuum smelting and variable pressure solidification forming aluminum alloy piece with ultra-thin wall and high gas tightness is provided, in which an induction heating furnace is set in a vacuum tank, a quartz crucible with thickness of 5˜8 mm is used; a preheated aluminum alloy ingot is placed in the crucible, side doors of the tank is closed, and a vacuuming processing is performed for the tank; the melt is filled from the bottom layer of the casting; when the melt reaches to the top, the main valve and the air-release valve are turned on until the inside and outside pressures are consistent, and then the casting is taken out. The requirement of high air tightness for vacuum tank is reduced, and aluminum alloy casting with high quality can be obtained at lower cost.

Abstract: Disclosed herein is an orthopedic implant device comprising a porous structure, approximating the shape of a bone, and having modulus of elasticity similar to that of said bone. Further disclosed herein is a method of treating injuries or diseases affecting bones or muscles comprising providing an orthopedic implant device, wherein the orthopedic implant device comprising a porous structure, approximating the shape of a bone, and having a modulus of elasticity similar to that of bone, and using the orthopedic implant device to treat injuries and diseases affecting bones and muscles in a mammal. Further disclosed herein is a method of manufacturing an orthopedic implant device using an additive manufacturing method comprising the steps: (a) providing a 3-dimensional model of the orthopedic implant device; (b) inputting the 3-dimensional model to an additive manufacturing device; and (c) using the additive manufacturing device to manufacture the orthopedic implant device.

Abstract: A combustor panel having a plurality of cooling flow paths formed between the outer surface and the inner surface of the combustor panel. The cooling flow paths have inlets that open at the outer surface and introduce a cooling medium into their interior, and outlets that open at the inner surface and discharge the cooling medium flowing through their interior. Among the plurality of cooling flow paths, each of plurality of cooling flow paths extending from a position along the edge of an aperture of the combustor panel forms an aperture-vicinity flow path. Among the plurality of aperture-vicinity flow paths, each of the aperture-vicinity flow paths for which the inlet is formed closer to the aperture than the outlet forms an aperture-side inlet flow path. The number of the aperture-side inlet flow paths is greater than one-half of the all of the aperture-vicinity flow paths.

Abstract: An adsorptive cooling system includes: a first highly adsorptive structure positioned to receive thermal energy from a thermal energy source, including: a first substrate; and a first metal-organic framework (MOF) coupled to the first substrate and adapted for adsorbing and desorbing a refrigerant under predetermined thermodynamic conditions; a second highly adsorptive structure positioned to receive thermal energy from the thermal energy source including: a second substrate; and a second MOF coupled to the second substrate and adapted for adsorbing and desorbing a refrigerant under predetermined thermodynamic conditions; a cooling unit; and a circulation system adapted for circulating refrigerant from the first highly adsorptive structure and the second highly adsorptive structure to the cooling unit to provide cooling from the thermal energy source and to return the refrigerant to at least one of the first highly adsorptive structure and the second highly adsorptive structure.

Abstract: A method of manufacturing a sandwich structure having an open cellular core and a fluid-tight seal surrounding the core includes coupling a mold to a first facesheet to define a reservoir. The method also includes irradiating a volume of photo-monomer in the reservoir with a series of vertical collimated light beams to form a cured, solid polymer border extending around a periphery of the first facesheet. The method also includes irradiating a remaining volume of photo-monomer in the reservoir with a series of collimated light beams to form an ordered three-dimensional polymer microstructure core defined by a plurality of interconnected polymer optical waveguides coupled to the first facesheet and surrounded by the cured, solid polymer border. The method further includes coupling a second facesheet to the ordered three-dimensional microstructure core and the cured, solid polymer border to form the sandwich structure.

Abstract: A nondestructive bond strength testing method, including: coupling an expendable device to a structure under test, the expendable device including a patterned planar array of exploding bridge wires; simultaneously vaporizing the patterned planar array of exploding bridge wires by applying a pulse of electrical energy to the patterned planar array of exploding bridge wires; and sensing an initial disbonding signature of the structure under test.

Abstract: A method of forming a hybrid metal composite structure including at least one metal ply. The method includes forming at least one metal ply, forming the at least one metal ply comprising forming at least one perforation in the at least one metal ply, abrasively blasting at least one surface of the at least one metal ply to coarsen the at least one surface of the metal ply, and exposing the at least one metal ply to at least one of an acid or a base. The method further includes disposing at least one fiber composite material structure adjacent the at least one metal ply. Related methods of forming a portion of a rocket case and related hybrid metal composite structures are also disclosed.

Abstract: A method of constructing a vehicle component includes depositing a layer of a first metal, extruding a filament of a second metal onto the layer, and depositing a second layer of the first metal on the filament.

Abstract: A friction stir welded structure includes first and second members. The first member has a base defining opposed first and second surfaces, and spaced first and second walls extending outwardly from the second surface of the base to define a receptacle therebetween. The second member includes an elongate rib extending from a root portion to a first tip portion, the root portion having a uniform root portion thickness and the first tip portion having a first tip portion thickness not greater than the root portion thickness. The first tip portion is sized for insertion into the receptacle and shaped conformally with the receptacle so that the first tip portion engages a closed end of the receptacle. A friction stir weld joint extends through the base and at least portions of the first and second walls of the first member and into the first tip portion of the second member, thereby to join the first and second members.

Abstract: One example provides a method of manufacturing. The method comprises printing multiple layers comprising a metal material by an additive manufacturing technique, wherein each of the multiple layers comprises an array of cavities each having a cross-section of a polygon; and assembling at least two of the multiple layers to form an article having an array of three-dimensional hollow cells collectively having a honeycomb structure.

Abstract: A heat shield assembly including a skin panel and a stiffener including a base portion and a bead portion protruding from the base portion, wherein the base portion is connected to the skin panel to define a bead volume between the bead portion and the skin panel.

Abstract: In a die-substrate assembly, a copper inter-component joint is formed by bonding corresponding copper interconnect structures together directly, without using solder. The copper interconnect structures have distal layers of (111) crystalline copper that enable them to bond together at a relatively low temperature (e.g., below 300° C.) compared to the relatively high melting point (about 1085° C.) for the bulk copper of the rest of the interconnect structures. By avoiding the use of solder, the resulting inter-component joint will not suffer from the adverse IMC/EM effects of conventional, solder-based joints. The distal surfaces of the interconnect structures may be curved (e.g., one concave and the other convex) to facilitate mating the two structures and improve the reliability of the physical contact between the two interconnect structures. The bonding may be achieved using directed microwave radiation and microwave-sensitive flux, instead of uniform heating.

Abstract: A fuel and nanodiamond mixture includes a fuel for combustion and a fuel additive in the form of nanodiamonds mixed into the fuel to be dispersed throughout the fuel.

Abstract: A wire grid device having transmission power characteristics and a power extinction ratio in a terahertz wave band that cannot be achieved conventionally. A cutout is formed between one end and an opposite end of a rectangular metal thin plate to form a plurality of grid plates each having an elongated grid part between the one end and the opposite end. The grid plates are stacked in such a manner that the grid parts of the grid plates are spaced at a given interval and face each other, thereby forming a grid plate stack. In this case, spacers are inserted between one ends and between opposite ends of adjacent ones of the grid plates to form parallel flat plates configured by the grid parts. The grid plate stack forming the parallel flat plates operates as a polarizer for a terahertz wave band.

Abstract: The present invention is concerned with a method of manufacturing a tissue-integration device, and a tissue-integration device so produced, the method comprising the steps of wrapping a porous sheet of material around a mandrel in order to create overlapping layers of the porous sheet material, the wrapped mandrel then being placed in a mould in order to apply pressure and heat to the overlapping layers in order to effect the lamination thereof such as to form a device having spaces defined by overlapping pores of the adjacent layers.

Abstract: A joining method for joining a first member and a second member is provided. The joining method includes a step of providing a first brazing layer on the first member by plating, a step of providing a second brazing layer on the first brazing layer by plating, a step of arranging the first member and the second member to oppose each other across the first brazing layer and the second brazing layer, and a step of melting the first brazing layer and the second brazing layer to join the first member and the second member which are arranged to oppose each other.

Abstract: A hydrogen generator is provided for generating hydrogen gas for a fuel cell stack. The hydrogen generator includes a container, and a liquid reactant storage area configured to contain a liquid including a first reactant. The hydrogen generator also includes a reaction area within the container, and a solid containing a second reactant within the reaction area and having a concentration gradient that varies along an axis such as length of the solid. The hydrogen generator further includes a liquid delivery member for delivering the liquid to the solid in the reaction area to generate hydrogen. The concentration gradient controls a reaction rate of the first and second reactants.

Abstract: Methods for electrochemical deposition of a metal coating on a metal substrate are described. The method may use an ionic liquid as an electrolyte, and the substrate may comprise a first metallic element. Method steps may include pretreating the substrate by etching in an ionic liquid containing metal ions of a second metallic element, removing metal ions of the first metallic element from the substrate, wherein the metal ions of the first metallic element are received by the ionic liquid, depositing a transition layer on the substrate from the ionic liquid, wherein metal ions of the first and second metallic elements are incorporated in the transition layer, and depositing a coating on the transition layer by electrochemical deposition from an ionic liquid containing ions of the second metallic element.

Abstract: A method includes disposing a braze material adjacent a first body and a second body; heating the braze material and forming a transient liquid phase; and transforming the transient liquid phase to a solid phase and forming a bond between the first body and the second body. The braze material includes copper, silver, zinc, magnesium, and at least one material selected from the group consisting of nickel, tin, cobalt, iron, phosphorous, indium, lead, antimony, cadmium, and bismuth.

Abstract: A method includes disposing a braze material between a first body and a second body. The braze material includes a first composition and a second composition. The second composition has a melting point higher than the first composition. The method also includes heating the braze material to a brazing temperature between the melting points of the first and second materials and maintaining the braze material at the brazing temperature for a period of time to transform a transient liquid phase to a solid phase, forming a bond between the first body and the second body. A braze material for securing solid bodies includes a first composition and a second composition. The first composition includes at least one element selected from the group consisting of indium, tin, zinc, and magnesium. An earth-boring tool includes a first body, a second body, and a braze material bonding the second body to the first body.

Abstract: A system for elastically compensating for wear, thermal expansion and misalignment comprises a ring located between a housing and a pin in the bore of the housing. The ring has a backing layer, an expanded grid structure having a plurality of openings, a low friction layer penetrated into the openings of the expanded grid structure, and adhesive for bonding the backing layer, expanded grid structure and low friction layer together to provide elastic deformation of the ring between the housing and pin.

Abstract: A metal honeycomb carrier comprising a metal outer casing having inserted thereinto a metal honeycomb structure consisting of a metallic flat foil and a metallic corrugated foil, wherein perforations in an opening ratio of 30 to 60% are provided in either one or both of the flat foil and the corrugated foil.

Abstract: A micro-truss based blast protection apparatus. In one embodiment, the blast protection apparatus includes a three-dimensional (3D) ordered truss core between a first face plate and a second face plate. The 3D ordered truss core includes first truss elements defined by first self-propagating polymer waveguides and extending along a first direction, second truss elements defined by second self-propagating polymer waveguides and extending along a second direction, and third truss elements defined by third self-propagating polymer waveguides and extending along a third direction. The first, second, and third truss elements interpenetrate each other at a plurality of nodes to form a continuous material. The first, second, and third truss elements define an open space for providing a densification in response to a force applied to the first face plate and/or the second face plate, and the 3D ordered truss core is self-supporting.

Abstract: A honeycomb body includes at least a housing and a honeycomb structure with a multiplicity of channels. The honeycomb structure includes at least one at least partially structured metallic layer forming connecting points which fix the honeycomb structure. A cross section of the honeycomb structure has radial zones with connecting points. At least 1% and at most 20% of inner contact points of the at least one at least partially structured metallic layer in at least one of the zones forms a connecting point in the cross section. The channels have a different channel cross section in at least two of the radial zones. A motor vehicle having the honeycomb body is also provided.

Abstract: The present invention describes composite rods keeping two elements apart a determined distance carrying the loads between them, such as railways, industrial premises, etc. Besides, the manufacturing method thereof and the tool involved in this process are also described.

Abstract: A shear layer for a shear band that is used in a tire is provided that has multiple cells having a chiral configuration. The chiral configuration may be hexagonal or tetrachiral or have other configurations.

Abstract: A method of continuous manufacture of a composite hollow board material comprising a first surface and a second surface, and between the first and second surfaces a plurality of distance members is disclosed. The method comprises providing material for the first surface from a first reel via a first guide roller towards an output lane; providing material for the second surface from a second reel via a second guide roller towards the output lane; and providing material for the distance members from a third reel towards the output lane such that the distance members comprises strips arranged, at any cross section perpendicular to the first and second surfaces and the direction of the output lane, perpendicular to the first and second surfaces and continuous along the output lane.

Abstract: A structure 1 is provided with a core layer 2 where a plurality of polygonal-cylindrical or circular-cylindrical cells S are disposed adjoiningly inside and skin layers 3, 4 that are provided on the upper and lower surfaces of the core layer 2. Communication portions 6 for communicating with adjacent cells S are formed in the core layer 2. A molded article is formed by providing a bent portion to the structure 1.

Abstract: A honeycomb body includes wound and/or stacked layers having a geometric center axis, a cavity rotationally symmetrically around the center axis and an outer lateral surface. Each layer extends approximately concentrically around the axis. At least one of the layers is at least partially structured forming channels through which a fluid can flow. The channels extend from the cavity outward to the outer lateral surface at a non-right cone angle to the axis. The channels have a cross-section changing along the channels from inside to outside. At least one structured layer and at least one intermediate layer are alternatingly disposed and helically layered. The structure height of the structured sheet-metal layer forming the channels is substantially constant and channel cross-sectional areas increase from inside to outside. The intermediate layer can be made of simple wires or of specially cut or folded smooth sheet-metal layers.

Abstract: In accordance with various example embodiments, an apparatus includes two or more circuit nodes and a conductive material that is located between and configured to electrically couple the circuit nodes. The conductive material includes a network of elongated portions of at least one electrospun Cu-based nanostructure. Each elongated portion has an aspect ratio of at least 50,000 and a length that is greater than 100 microns, and at least one fused crossing point that joins with a fused crossing point of another of the elongated portions. The network of elongated portions is distributed and aligned in the conductive material to set a conductance level and a transparency level along the network, along at least one direction.

Abstract: A metal nanonetwork includes metal nanostructures that are joined by metallic bond. The joined part between the metal nanostructures includes a fillet part. In the joined part between the metal nanostructures, the distance between the central axis of one metal nanostructure and the central axis of another metal nanostructure is smaller than the sum of the radii of both metal nanostructures. The metal nanostructure is a metal nanowire. A first method for producing the metal nanonetwork includes a process of forming an oxide film on the outermost surface of the metal nanostructure, and a process of reducing the oxide film at the joined parts of a plurality of the metal nanostructures to thereby join the metal nanostructures.

Abstract: A sandwich structure is provided that includes a corrugated layer with at least one core layer (structure) made of a periodic array of adjacent truncated upward facing peaks and truncated downward facing valleys. Each truncated peak has a bonding land of an area A1. Each truncated valley has a bonding land of an area A2. A ratio of A1/A2 is less than 2. A distance D is between neighboring peaks, and a distance D is also between neighboring valleys. The corrugated layer is made from an initially flat sheet thickness of t. A first sheet layer is physically coupled to bonding lands of the truncated peaks. A second sheet layer is physically coupled to bonding lands of the truncated valleys.

Abstract: Compositions and methods for making a three dimensional structure comprising: designing a three-dimensional structure; melting the three-dimensional structure from two or more layers of a metal powder with a high energy electron or laser beam is described herein. The position where the metal is melted into the structure is formed along a layer of metal powder, wherein the location and intensity of the beam that strikes the metal layer is based on the three-dimensional structure and is controlled and directed by a processor. The instant invention comprises a novel dry state sonication step for removing metal powder that is not melted from the three dimensional structure.