SYSTEMS AND METHODS FOR FINISHING ADDITIVELY MANUFACTURED

PARTS

CROSS-REFERENCE

[0001] This application claims priority to U.S. Provisional Patent Application No.

62/757,836, which was filed on November 9, 2018. The contents of which is incorporated by reference into this specification.

FIELD OF USE

[0002] The present disclosure relates to a system and method for producing lattice supports capable of degradation utilizing a voltage potential, and to an article produced therefrom. In certain embodiments, the system and method are applied in an additive manufacturing process.

BACKGROUND

[0003] It can be desirable to incorporate finishes to metallic parts for aesthetic features and/or to meet end use specifications. Conventionally manufactured metallic parts can include post production surface finishing/ surf ace modification parameters including, to name a few: surface finish (surface roughness), and/or surface treatment/modification (e.g.

anodized layer, electroplating). Generally, and in additive manufacturing, there are challenges in providing suitable support to an object during its manufacture.

SUMMARY

[0004] According to one aspect of the present disclosure, a method is provided. The method comprises forming a part configured as a first electrode from metallic powder in a powder bed deposition region of an additive manufacturing apparatus. The part is restrained in the powder bed deposition region by an open-cell lattice formed from the metallic powder. The open-cell lattice comprises an unbound region and a bound region. The unbound region is adapted to form a void. A frame is formed and configured as a second electrode from the metallic powder in the powder bed deposition region of the additive manufacturing apparatus The frame is in communication with and is adapted to restrain the open-cell lattice. A voltage potential is created between the part as the first electrode and the frame as the second electrode. The open-cell lattice is degraded utilizing at least one of ohmic heating and electrochemical degradation.

[0005] According to another aspect of the present disclosure, an article of manufacture produced by an additive manufacturing process is provided. The article comprises an additively manufactured part, an open-cell lattice, and a frame. The additively manufactured part is configured as a first electrode. The open-cell lattice is in communication with at least a portion of the part and adapted to restrain the part. The open-cell lattice comprises an unbound region and a bound region. The unbound region is adapted to form a void. The frame is in communication with and adapted to restrain the open-cell lattice. The frame is configured as a second electrode and is disposed in a position in relation to the part adapted for establishing a voltage potential between the frame and the part.

[0006] According to yet another aspect of the present disclosure, a powder bed additive manufacturing system is provided. The system comprises a powder bed, a powder deposition module, a joining module, and an electrical power source. The powder bed deposition region is adapted to receive layers of metallic powder and comprises a powder bed deposition surface. The powder deposition module is adapted to dispose layers of metallic powder in the powder bed deposition region. The joining module is adapted to process metallic powder disposed in the powder bed deposition region to thereby form a part, an open-cell lattice, and a frame from the metallic powder. The open-cell lattice is in communication with at least a portion of the part and is adapted to restrain the part in the powder bed deposition region.

The open-cell lattice comprises an unbound region and a bound region. The unbound region is adapted to form a void. The electrical power source is adapted to degrade the open-cell lattice utilizing at least one of ohmic heating and electrochemical degradation.

[0007] According to one aspect of the present disclosure, a method is provided. The method comprises providing a part configured as a first electrode from metallic powder in a powder bed deposition region of an additive manufacturing apparatus. The part is restrained in the powder bed deposition region by an open-cell lattice formed from the metallic powder. The open-cell lattice comprises an unbound region and a bound region. The unbound region is adapted to form a void. A frame is formed and configured as a second electrode from the metallic powder in the powder bed deposition region of the additive manufacturing apparatus. The frame is in communication with and is adapted to restrain the open-cell lattice. A current is directed from an anodic surface to a cathodic surface to remove at least a portion of the open-cell lattice, thereby providing a surface finished part.

[0008] It is understood that the inventions disclosed and described in this specification are not limited to the aspects summarized in this Summary. The reader will appreciate the foregoing details, as well as others, upon considering the following detailed description of various non-limiting and non-exhaustive aspects according to this specification.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The features and advantages of the examples, and the manner of attaining them, will become more apparent, and the examples will be better understood, by reference to the following description taken in conjunction with the accompanying drawings, wherein:

[0010] FIGs. 1 A-B are a flow chart of a non-limiting embodiment of a method according to the present disclosure for forming a structure comprising a part, an open-cell lattice, and a frame;

[0011] FIG. 2A is a perspective view of a non-limiting embodiment of a structure according to the present disclosure;

[0012] FIG. 2B is an exploded perspective view of the structure of FIG. 2A with the open cell lattice and keyways removed;

[0013] FIG. 2C is a cross-sectional view cut along line A-A in FIG 2A;

[0014] FIG. 2D is a cross-sectional view cut along line A-A in FIG. 2A, where the keyways are not inserted into the slots;

[0015] FIG. 2E is a cross-sectional detail view of a region of the structure of FIG. 2A; [0016] FIG. 3 A is a detail view of the area B in FIG. 2E;

[0017] FIG. 3B is a non-limiting embodiment of the structure of FIG. 3 A after degradation of the open-cell lattice;

[0018] FIG. 3C is a non-limiting embodiment of the structure of FIG. 3B after the struts have been broken and discontinuities have been formed; [0019] FIG. 3D is a non-limiting embodiment of the structure of FIG. 3C after the open cell lattice has been removed;

[0020] FIG. 4 is a schematic depiction showing certain aspects of a non-limiting embodiment of an additive manufacturing system according to the present disclosure; and

[0021] FIG. 5 is a schematic depiction showing aspects of a non-limiting embodiment of a removal module according to the present disclosure.

[0022] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate certain embodiments, in one form, and such exemplifications are not to be construed as limiting the scope of the appended claims in any manner.

DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS

[0023] Various embodiments are described and illustrated herein to provide an overall understanding of the structure, function, and use of the disclosed methods, systems, and articles. The various embodiments described and illustrated herein are non-limiting and non- exhaustive. Thus, the invention is not limited by the description of the various non-limiting and non-exhaustive embodiments disclosed herein. Rather, the invention is defined solely by the claims. The features and characteristics illustrated and/or described in connection with various embodiments may be combined with the features and characteristics of other embodiments. Such modifications and variations are intended to be included within the scope of this specification. As such, the claims may be amended to recite any features or characteristics expressly or inherently described in, or otherwise expressly or inherently supported by, this specification. Further, Applicant reserves the right to amend the claims to affirmatively disclaim features or characteristics that may be present in the prior art. The various embodiments disclosed and described in this specification can comprise, consist of, or consist essentially of the features and characteristics as variously described herein.

[0024] Any patent, publication, or other disclosure material identified herein is incorporated herein by reference in its entirety unless otherwise indicated but only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material expressly set forth in this specification. As such, and to the extent necessary, the express disclosure as set forth in this specification supersedes any conflicting material incorporated by reference herein. Any material, or portion thereof, that is said to be incorporated by reference into this specification, but which conflicts with existing definitions, statements, or other disclosure material set forth herein, is only incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. Applicant reserves the right to amend this specification to expressly recite any subject matter, or portion thereof, incorporated by reference herein.

[0025] Any references herein to“various embodiments,”“some embodiments,”“one embodiment,”“an embodiment,” or like phrases, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases“in various embodiments,”“in some embodiments,”“in one embodiment,”“in an embodiment,” or like phrases, in the

specification do not necessarily refer to the same embodiment. Furthermore, the particular described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features, structures, or characteristics of one or more other embodiments without limitation. Such modifications and variations are intended to be included within the scope of the present embodiments.

[0026] In this specification, unless otherwise indicated, all numerical parameters are to be understood as being prefaced and modified in all instances by the term“about,” in which the numerical parameters possess the inherent variability characteristic of the underlying measurement techniques used to determine the numerical value of the parameter. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter described herein should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0027] Also, any numerical range recited herein includes all sub-ranges subsumed within the recited range. For example, a range of“1 to 10” includes all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10. Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, Applicant reserves the right to amend this specification, including the claims, to expressly recite any sub-range subsumed within the ranges expressly recited. All such ranges are inherently described in this specification.

[0028] The grammatical articles“a,”“an,” and“the,” as used herein, are intended to include“at least one” or“one or more,” unless otherwise indicated, even if“at least one” or “one or more” is expressly used in certain instances. Thus, the foregoing grammatical articles are used herein to refer to one or more than one (i.e., to“at least one”) of the particular identified elements. Further, the use of a singular noun includes the plural, and the use of a plural noun includes the singular, unless the context of the usage requires otherwise.

[0029] “Additive manufacturing” refers to“a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies,” as defined in ASTM F2792-l2a, entitled“Standard Terminology for Additively Manufacturing Technologies.” Non-limiting examples of additive manufacturing processes for producing parts and other articles from feedstocks include, for example, binder jet additive manufacturing (BJAM), direct metal laser sintering (DMLS), selective laser melting (SLM), selective laser sintering (SLS), and electron beam melting (EBM).

[0030] As used herein,“powder” refers to a material comprising a plurality of particles. Powder may be used in a powder bed in an additive manufacturing system or process to produce a tailored alloy product via additive manufacturing. Powder, as used herein, may comprise a single material or a blend of two or more materials.

[0031] As used herein, a“median particle size” of a powder refers to the diameter at which 50% of the volume of the particles in the powder has a smaller diameter (e.g., D50).

As used herein, median particle size is determined in accordance with ASTM standard B822.

[0032] As used herein,“restrain” comprises supporting an object and/or preventing movement of an object. For example, restraining an object can comprise preventing movement of the object in a powder bed deposition region of an additive manufacturing system in relation to the powder deposition surface. In various embodiments, restraining a part can comprise supporting the structural integrity of the object so that the object does not crack, spall, and/or erode. In various embodiments, restraining a part can comprise supporting a layer of the object currently being formed in a powder bed deposition region such that the molten powder can be supported and/or prevented from moving. In various embodiments, restraining a part can comprise supporting an intermediate part (e.g., partially built) to dissipate accumulation of residual stresses in the intermediate part. In various embodiments, the article may undergo significant residual stress build up, distortion, and/or other stress/strain related considerations.

[0033] When producing an article with an additive manufacturing system or method, the article may comprise, for example, particles of a feedstock that are not properly joined together, and the article may require further processing to produce the article. As such, there may be challenges to ensure that an additively manufactured article is suitably supported during and on completion of the manufacturing process, so that the article does not, for example, crack, spall, or erode. In various embodiments, the article may undergo significant residual stress build up, distortion, and/or other stress/strain related considerations.

Additionally, some conventional additive manufacturing techniques can provide insufficient restraint of the additively manufactured part. Due to the insufficient restraint, the additively manufactured part may move during manufacture and part defects such as cracking may occur.

[0034] The present inventors provide herein a system and a method for producing an open-cell lattice that can restrain an additively manufactured part during manufacture, and which is configured with specific geometries and/or thicknesses for tailored removal operations (e.g., capable of removal). The open-cell lattice, according to the present disclosure, can reduce the time and cost required to manufacture additively manufactured parts and can reduce, prevent, and/or eliminate the occurrence of defects in such parts.

[0035] FIGs. 1 A-B are a flow chart of a non-limiting embodiment of a method for forming a structure comprising a part, an open-cell lattice, and a frame, according to the present disclosure. With reference to FIGs. 1 A-B, a part is formed from metallic powder in a powder bed deposition region of an additive manufacturing apparatus (102). In various

embodiments, the powder can comprise one or more of titanium particles, titanium alloy particles, aluminum particles, aluminum alloy particles, nickel particles, nickel alloy particles, iron particles, iron alloy particles, cobalt particles, cobalt alloy particles, copper particles, copper alloy particles, molybdenum particles, molybdenum alloy particles, magnesium particles, magnesium alloy particles, tantalum particles, tantalum alloy particles, chromium particles, chromium alloy particles, tungsten particles, tungsten alloy particles, zinc particles, zinc alloy particles, silver particles, silver alloy particles, chromium particles, chromium alloy particles, tin particles, tin alloy particles, gold particles, gold alloy particles, platinum particles, platinum alloy particles, zirconium particles, and zirconium alloy particles.

[0036] In various embodiments, the metallic powder can have a median particle size of at least 50 nm, such as, for example, at least 1 pm, at least 5 pm, at least 10 pm, at least 15 pm, at least 20 pm, at least 25 pm, at least 30 pm, at least 50 pm, at least 60 pm, at least 65 pm, or at least 105 pm. In various embodiments, the metallic powder can have a median particle size of no greater than 325 pm, such as, for example, no greater than 300 pm, no greater than 275 pm, no greater than 250 pm, no greater than 225 pm, no greater than 200 pm, no greater than 180 pm, no greater than 175 pm, no greater than 150 pm, no greater than 125 pm, no greater than 100 pm, no greater than 90 pm, no greater than 70 pm, no greater than 65 pm, no greater than 60 pm, no greater than 50 pm, no greater than 45 pm, no greater than 30 pm, no greater than 10 pm, or no greater than 1 pm. In various embodiments, the metallic powder can have a median particle size in a range of 50 nm to 325 pm, such as, for example,

1 pm to 325 pm, 5 pm to 325 pm, 10 pm to 100 pm, 105 pm to 180 pm, 20 pm to 50 pm,

60 pm to 90 pm, 50 pm to 100 pm, 10 pm to 150 pm, 15 pm to 45 pm, 20 pm to 65 pm,

25 pm to 45 pm, 50 pm to 150 pm, 65 pm to 90 pm, 10 pm to 200 pm, 5 pm to 30 pm,

30 pm to 90 pm, or 5 pm to 50 pm.

[0037] Again referring to FIGs. 1 A-B, an open-cell lattice comprising a bound region and an unbound region is formed in communication with at least a portion of the part (104). The open-cell lattice can contact an exterior surface of the part and can restrain the part in the powder bed deposition region of the additive manufacturing apparatus. For example, the open-cell lattice can support and prevent movement of the part in the powder bed deposition region.

[0038] A frame is formed in communication with the open-cell lattice (106). The frame can contact the open-cell lattice and restrain the open-cell lattice. For example, the frame can support and prevent movement of the open-cell lattice in the powder bed deposition region, which in turn supports and prevents movement of the part in the powder bed deposition region. In various embodiments, the frame can be formed with a slot suitable to receive a key way (108). [0039] Forming the components of the structure (e.g., part, open-cell lattice, and frame) can occur in multiple steps. For example, a layer of metallic powder can be deposited in a powder bed deposition region and a selected region or regions of the deposited powder layer can be affixed (e.g., bound and/or fused) together to form a layer, including the affixed portions of the components of the structure present in the respective layer. In various embodiments, the selected region or regions of the deposited powder layer can be affixed to an underlying, previously deposited layer, if any, in the powder bed deposition region. The sequence of depositing metallic powder and then affixing a selected region can be repeated as needed to build up and form the structure, which includes the part, the open-cell lattice, and the frame (110). In various embodiments, steps (102), (104), (106), and (108) can be performed in any order or simultaneously. In some embodiments, step (104) occurs prior to step (102) and step (106) occurs prior to step (104).

[0040] With further reference to FIGs. 1 A-B, the part can be configured as a first electrode, and the frame can be configured as a second electrode (112). The part and frame can be in electrical communication via the open-cell lattice. The first and second electrode can differ. In various embodiments, the part can be configured as an anode (e.g., positively charged electrode) and the frame can be configured as a cathode (e.g., negatively charged electrode). In various embodiments, a contact can be connected in electrical communication with the part. For example, the contact can comprise a key way, a support section, and a secondary electrode. In various embodiments, a secondary electrode can be connected in electrical communication with the frame.

[0041] The unbound region of the open-cell lattice can be a passage through the open-cell lattice that can convey unbound and/or unfused (i.e., loose) powder out of the open-cell lattice and/or out of the structure. The removal of the loose powder from the unbound region can form a void in the open-cell lattice (114). The void can be capable of receiving an electrolyte.

[0042] A key way can be inserted into the slot of the frame and thereby restrain the movement of the frame (116). For example, the key way can contact at least two sections of the frame and limit movement of the contacted frame sections with respect to one another.

[0043] In order to remove the loose powder in the unbound region, the structure can be subject to at least one powder removal method, such as re-positioning the structure, re- orienting the structure, shaking the structure, vibrating the structure, vacuuming the loose powder from the unbound region, and flowing a pressurized fluid into the unbound region. For example, the structure can be removed from the powder bed deposition region and positioned such that loose powder is allowed to drain out of the structure from the unbound region of the open-cell lattice. Removal of the loose powder from the unbound region of the open-cell lattice provides a void in the open-cell lattice.

[0044] After removal of the loose powder, a voltage potential can be created between the part as the first electrode (e.g., anode) and the frame as the second electrode (e.g., cathode), thereby degrading the open-cell lattice utilizing an electric current (118). The degradation of the open-cell lattice can utilize at least one of ohmic heating (120) and electrochemical degradation (122). In embodiments utilizing ohmic heating (120) to degrade the open-cell lattice, an electric current can be passed through the open-cell lattice by connecting the part as the first electrode and the frame as the second electrode to an electrical power source (e.g., direct current (DC) or alternating current (AC)). The open-cell lattice can be heated by passage of current and thereby degrade. In various embodiments, the open-cell lattice can become softened and/or melt due to the ohmic heating.

[0045] In embodiments utilizing electrochemical degradation (122) to degrade the open cell lattice, an electrolyte can be passed through the void and an electric current can be created between the part and the frame to degrade the bound region of the open-cell lattice, freeing the part from the lattice. For example, the portion of the structure to be eroded (e.g., the part) can be configured as the anode and connected to the positive terminal of a DC electrical power source. The frame can be configured as a cathode and connected to the negative terminal of the DC electrical power source. The electrolyte can be pumped into the void and/or the structure can be submerged into a volume of the electrolyte to allow the electrolyte to enter the void. The voltage potential can be created and, together with the electrolyte, can degrade the open-cell lattice by creating an electric current between the part and the frame. In various embodiments, the voltage potential can selectively ohmically heat the open-cell lattice and surrounding electrolyte such that the reaction rate of a chemical degradation of the open-cell lattice via the electrolyte increases compared to a degradation of the part and/or frame. In various embodiments, the voltage potential can electrochemically degrade the open-cell lattice through dissolution of the bound region of the open-cell lattice into the electrolyte utilizing an electric current. In various embodiments, steps (120) (ohmic heating) and (122) (electrochemical degradation) can occur in sequence or simultaneously, or only one of those steps may occur.

[0046] The electrolyte can be any fluid substance that can be ionically conductive and, in various embodiments, chemically degrade the open-cell lattice (e.g., an etchant). In various embodiments, the electrolyte can comprise a solution of an acid or a salt. The electrolyte can comprise one or more of a mineral acid (e.g., hydrofluoric acid, hydrochloric acid, nitric acid, phosphoric acid, chromic acid, perchloric acid, fluoroboric acid, boric acid), an organic acid (e.g., acetic acid), an alkali hydroxide (e.g., sodium hydroxide, potassium hydroxide), an ammonium hydroxide (e.g., tetramethylammonium hydroxide), an organic hydroxide (e.g., choline hydroxide), an alkali metal carbonate (e.g., sodium carbonate), and alkali metal bicarbonate (e.g. sodium bicarbonate), an alcohol, trisodium phosphate, sodium nitrate, ammonium bifluoride, aluminum chloride, zinc chloride, sodium chloride, potassium chloride, sodium chlorate, and sodium tripolyphosphate. In various embodiments, the electrolyte can be a liquid solution. In various embodiments, an electrolyte solvent can be used for delivering the electrolyte to the void. For example, the solvent can comprise at least one of water, an alcohol, an acid, and glycerin. In various embodiments, the electrolyte can include an additive. For example, the electrolyte can comprise a hydrogen formation suppressant.

[0047] In various embodiments, steps (114) (removing loose powder from the unbound region to provide the void) and (118) (degrading the bound region of the open-cell lattice) can occur simultaneously. For example, passing the electrolyte into the unbound region of the open-cell lattice can remove the loose powder in the unbound region of the open-cell lattice, producing the void, and also facilitate degradation of the open-cell lattice.

[0048] Following ohmic heating (120) and/or electrochemical degradation (122), the open-cell lattice can be broken (e.g., no longer extending from the part to the frame) such that the electrolyte separates the part from the frame. The voltage potential can be maintained, and the open-cell lattice can continue to degrade from the part by electrochemical

degradation. In various embodiments, the larger the surface area of a feature in the open-cell lattice, the greater the dissolution rate of the feature into the electrolyte (e.g., removal).

[0049] The electrochemical degradation exposes an exterior surface of the part (124). The exposed surface can be smooth and etched and, in certain embodiments, can have a surface roughness smoother than a surface produced by a tool machining process. For example, the degradation of the open-cell lattice can remove the bound region of the open-cell lattice from the structure and create a void between the part and the frame such that the part can be facilely removed from the remaining portion of the structure. In various embodiments, the frame remains restrained upon degradation of the open-cell lattice by the keyways inserted into the slots of the frame. In various embodiments, the part can be in a finished state after the degradation of the open-cell lattice.

[0050] A secondary operation can be performed on the structure and exposed surface of the part (126). For example, a second voltage potential and a second electric current can be created between the part as anode and the frame as cathode. Creating the second voltage potential can comprise electropolishing the part utilizing the electrolyte, electroplating the part utilizing the electrolyte, and/or anodizing the part utilizing the electrolyte. The second voltage potential can be the same or different than the first voltage potential. For example, the first voltage potential may be maintained after the degradation of the open-cell lattice such that the exposed surface of the part can be electro polished and/or anodized. In various embodiments, creating the second voltage potential comprises configuring the part as cathode and the frame as anode in order to, for example, electroplate the part.

[0051] Referring to FIGs. 2A-E, non-limiting embodiments according to the present disclosure of a structure 200 comprising an open-cell lattice 204 capable of removal are provided. The structure 200 can be formed utilizing a powder bed additive manufacturing process. The structure 200 comprises an additively manufactured part 202, the open-cell lattice 204, and a frame 206. The frame 206 can be disposed in a position in relation to the part 202 adapted for establishing a voltage potential between the frame 206 and the part 202 via the open-cell lattice 204 and/or when the open-cell lattice 204 is removed. The structure 200 can comprise a metallic material, such as, for example, at least one of titanium, titanium alloy, aluminum, aluminum alloy, nickel, nickel alloy, iron, iron alloy, cobalt, cobalt alloy, copper, copper alloy, molybdenum, molybdenum alloy, magnesium, magnesium alloy, tantalum, tantalum alloy, chromium, chromium alloy, tungsten, tungsten alloy, zinc, zinc alloy, silver, silver alloy, chromium, chromium alloy, tin, tin alloy, gold, gold alloy, platinum, platinum alloy, zirconium, and zirconium alloy.

[0052] The open-cell lattice 204 can comprise a bound region 208 and an unbound region 210 (as shown in FIGs. 3A-D). The open-cell lattice 204 can be formed so that it is in communication with at least a portion of the part 202. For example, the open-cell lattice 204 can be in contact with the part 202 and can also be in contact with the frame 206. The open cell lattice 204 can surround the part 202 such that a minimal portion, if any, of the exterior surface of the part 202 is exposed prior to degradation of the open-cell lattice 204. For example, surface 202a of the part 202 can be partially or fully covered by open-cell lattice 204. In various embodiments, the open-cell lattice 204 can cover at least 10% of the external surface area of the part 202, such as, for example, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 99% of the external surface area of the part 202. In various embodiments, the open-cell lattice 204 can cover 100% or less of the external surface area of the part 202, such as, 99% or less, 90% or less, 80% or less, 70% or less, 60% or less, 50% or less, 40% or less, 30% or less, or 20% or less of the external surface area of the part 202.

[0053] The open-cell lattice 204 can be adapted to restrain the part 202 in the powder bed deposition region of an additive manufacturing system. For example, the open-cell lattice 204 can be adapted to support and prevent movement of the part 202 in the powder bed deposition region. The open-cell lattice 204 can be disposed between the frame 206 and the part 202 and can attach the part 202 to the frame 206. The frame 206 can be formed in communication with at least a portion of the open-cell lattice 204. In various embodiments, at least a portion of the frame 206 is formed in communication with the part 202. The part 202 can be rendered resistant to movement and supported such that minimal, if any, changes in a position of the part 202 in relation to a powder deposition platform of an additive manufacturing system occur during build-up of the part 202.

[0054] The open-cell lattice 204 can be configured for at least one of ohmic heating and electrochemical degradation. In various embodiments, the open-cell lattice can be configured for chemical degradation. For example, the geometry, width, interior open volume, pore size, strut width, and strut shape of the open-cell lattice 204 can be chosen to facilitate the ohmic heating, chemical degradation, and/or electrochemical degradation.

[0055] The frame 206 can comprise a single section or, as illustrated in FIGs. 2A-E, a plurality of sections such as, for example, a first section 206a, a second section 206b, a third section 206c, a fourth section 206d, a fifth section 206e, and a sixth section 206f. In various embodiments, the fifth section 206e of the frame 206 can be attached to the powder deposition platform of an additive manufacturing system. In various embodiments, all sections 206a-f can be separated from the part 202 by open-cell lattice 204. In various other embodiments, a section 206a-f can be directly attached to the part 202 with minimal, if any, open-cell lattice between the respective section 206a-f and the part 202. The directly attached section and the part 202 can have the same electrical potential, which can be a different electrical potential than the remaining sections of the frame 206. For example, section 206e can be directly attached to part 202, and part 202 and section 206e can have a first electrical potential, while sections 206a-d and 206f can have a second electrical potential different than the first electrical potential.

[0056] As used herein,“frame” refers to the entirety of a frame, such as a first section 206a, second section 206b, third section 206c, fourth section 206d, fifth section 206e, and sixth section 206f of frame 206, collectively, or to a frame comprising a single section. In embodiments where a frame having a single section is used, the part 202 may be configured such that the part 202 can be pulled out of the structure 200 in a single direction after degrading the open-cell lattice 204. For example, the part 202 may contain a positive draft and/or can be free of an undercut feature. In various embodiments, the frame 206 may be cut to aide in the removal of the part 202 from the structure 200 formed in the powder bed deposition region of an additive manufacturing apparatus or system. In embodiments where a plurality of sections are used to form the frame, the sections can be attached to each other, or one or more of the frame sections can be separated from other frame sections by the open-cell lattice 204. As illustrated in FIGs. 2A-E, sections 206a-f of frame 206 are separated from each other by the open-cell lattice 204. Separating sections 206a-f of frame 206 by the open cell lattice 204 and then degrading the open-cell lattice 204 can enable facile removal of the part 202 from the structure 200. For example, sections 206a-f of frame 206 may no longer be attached to one another upon degradation of the open-cell lattice 204, and the sections 206a-f of the frame 206 may fall apart, further exposing the part 202.

[0057] The frame 206 can be configured with a slot, such as slots 218. The slots 218 extend between two or more sections 206a-f of the frame 206. The slots 218 can comprise a void and can be disposed within the frame. The slots 218 may not contain open-cell lattice 204. The slots 218 can be capable of receiving keyways 220. For example, the keyways 220 can be inserted into slots 218 as shown in FIG. 2C. Upon insertion of a keyway 220 into a slot 218, the key way 220 may contact the frame 206 and can restrain the movement of the frame 206. For example, upon insertions of the keyways 220 into the slots 218, the sections 206a-f of the frame 206 may be restrained from movement upon degradation of the open-cell lattice 204. For example, each key way 220 can contact at least two sections of the frame 206 and limit movement of the contacted frame sections with respect to one another. Each slot 218 may have a key way 220 inserted therein, or less than all of slots 218 may have a key way inserted therein.

[0058] Referring to FIG. 2D, key ways 220 are shown not in contact with slots 218. For example, the key ways 220 may not yet have been inserted into slots 218 or the key ways 220 may have been removed from the slots 218. The keyways 220 can comprise at least one of a conductive material, a non-conductive material, and an electrode. In embodiments comprising a section of frame 206 directly attached to the part 202, keyways 220 that span the directly attached section and a non-directly attached section of frame 206 can comprise a non-conductive material in order to at least partially electrically isolate the directly attached section from the non-directly attached section of frame 206. The directly attached section and the non-directly attached section of frame 206 may be in electrical connection via the open-cell lattice 204. The at least partial electrical isolation can limit electric current through the keyways 220 when the voltage potential is created between the non-directly attached section of frame 206 and the part 202 (and corresponding directly attached section of frame 206). The partial electrical isolation can enhance the degradation of the open-cell lattice 204 and limit degradation of the keyways 220.

[0059] In various embodiments, defects in the frame 206 and the open-cell lattice 204 may not affect the quality of the part 202. Thus, the build quality of the frame 206 and the open cell lattice 204 can be reduced, which can reduce the time to produce the structure 200.

[0060] With reference to FIGs. 3A-D, the unbound region 210 of the open-cell lattice 204 can comprise loose powder. Once at least a portion of the loose powder is removed from the open-cell lattice 204, the unbound region 210 can provide a continuous passage within the open-cell lattice 204 that is open to an environment outside of an exterior surface of the structure 200. The unbound region 210 can be adapted to convey the loose powder through the passage to the environment. Upon conveyance (e.g., removal) of at least a portion of the loose powder from the unbound region 210, a void that was previously occupied by the removed loose powder can exist in the unbound region 210. The void can be suitable to receive an electrolyte and transport the electrolyte throughout an interior of the open-cell lattice 204. For example, the void may have a suitable pressure drop from the exterior surface of the structure 200 throughout the void such that fluid (e.g., electrolyte) is able to traverse throughout the void in the open-cell lattice 204. In various embodiments, the unbound region 210 is adapted to form a void that is a fluid passage. In various

embodiments, the unbound region 210 can be additively manufactured with at least a portion of void space.

[0061] As used herein, the“interior open volume” means the portion of the total volume of a component that is occupied by loose powder and void space formed by removal of at least a portion of the loose powder. For example, the interior open volume of the open-cell lattice 204 can equal the percentage of the overall volume of the open-cell lattice 204 that is occupied by the unbound region 210.

[0062] In various embodiments, the open-cell lattice 204 can comprise an interior open volume of at least 20% by volume based on the total volume of the open-cell lattice 204, such as, for example, at least 30% by volume, at least 40% by volume, at least 50% by volume, at least 60% by volume, at least 70% by volume, or at least 80% by volume, all based on the total volume of the open-cell lattice 204. In various embodiments, the open-cell lattice 204 can comprise an interior open volume no greater than 90% by volume based on the total volume of the open-cell lattice 204, such as, for example, no greater than 80% by volume, no greater than 70% by volume, no greater than 60% by volume, no greater than 50% by volume, no greater than 40% by volume, or no greater than 30% by volume, all based on the total volume of the open-cell lattice 204. In various embodiments, the open-cell lattice 204 can comprise an interior open volume in a range of 20% to 90% by volume based on the total volume of the open-cell lattice 204, such as, for example, 40% to 80% by volume, 20% to 50% by volume, 60% to 80% by volume, 40% to 60% by volume, or 30% to 70% by volume, all based on the total volume of the open-cell lattice 204.

[0063] As used herein,“pore size” of the open-cell lattice 204 refers to a cross-sectional dimension (e.g., width or diameter) of the unbound region 210 in a cross section of the open cell lattice 204.

[0064] In various embodiments, the open-cell lattice 204 can comprise a pore size of at least 100 pm, such as, for example, at least 200 pm, at least 300 pm, at least 400 pm, at least 500 pm, at least 1 mm, at least 1.5 mm, at least 2 mm, at least 3 mm, or at least 4 mm. In various embodiments, the open-cell lattice 204 can comprise a pore size no greater than 5 mm, such as, for example, no greater than 4 mm, no greater than 3 mm, no greater than 2 mm, no greater than 1.5 mm, no greater than 1 mm, no greater than 500 pm, no greater than 400 pm, no greater than 300 pm, or no greater than 200 pm. In various embodiments, the open-cell lattice 204 can comprise a pore size in the range of 100 pm to 5 mm, such as, for example, 200 pm to 1 mm, 1 mm to 2 mm, 500 pm to 2 mm, or 100 pm to 1 mm.

[0065] In various embodiments, the structure 200 can be a monolithic structure comprising or consisting of the part 202, the open-cell lattice 204, and the frame 206, such that there is minimally, if any, clear delineation of where one component starts and another component ends. In various embodiments, the frame 206 comprises a physical property that is the same as a physical property of the part 202 or different than a physical property of the part 202. For example, the frame 206 and the part 202 can be constructed from the same material (e.g., metallic powder) utilizing the same build parameters. The physical property can comprise porosity, density, composition, and/or microstructure. The build parameters can comprise, for example, at least one of power level (e.g., laser power, electron beam power), hatch spacing, scan velocity, and raster pattern.

[0066] In various embodiments, a bound region 208 of the open-cell lattice 204 comprises a physical property that is the same as or different than a physical property of the part 202. For example, the part 202 and a bound region 208 of the open-cell lattice 204 can be constructed from the same material (e.g., metallic powder) utilizing the same build parameters. In other embodiments, the bound region 208 of the open-cell lattice 204 can be manufactured utilizing at least one build parameter different than that used to produce the part 202, such that the bound region 208 of the open-cell lattice 204 can be more susceptible to degradation than the part 202. For example, the microstructure of the open-cell lattice 204 can be adapted to be degraded. The microstructure of the open-cell lattice 204 can have a different grain structure than the grain structure of the part 202. In various embodiments, the open-cell lattice 204 has minimal if any non-metallic grain boundaries or inclusions such that the electrical conductivity of the open-cell lattice 204 is suitable for degradation via ohmic heating and/or electrochemical degradation.

[0067] The bound region 208 of the open-cell lattice 204 comprises a first layer 212, a strut 214, and optionally a second layer 216. In various embodiments, the bound region 208 was produced from metallic powder during the additive manufacturing process. The bound region 208 can be a single monolithic structure adapted to restrain the part 202 in the powder deposition region of the additive manufacturing apparatus or system. For example, the bound region 208 physically supports the part 202 and can transfer stresses from the part 202 into the frame 206 and/or the powder deposition surface of an additive manufacturing system.

[0068] With reference to FIG. 3 A, in various embodiments, the open-cell lattice 204 can comprise a uniform thickness adapted to be degraded prior to degrading the part 202. For example, struts 214 of the open-cell lattice 204 can have substantially the same thickness through the open-cell lattice 204 such that most, if not all, of the struts 214 are removed at a similar, if not the same, rate. In various embodiments, the first layer 212 can have substantially the same thickness throughout the open-cell lattice 204 and can surround the exterior surface of the part 202 continuously. The electrolyte can flow throughout the open cell lattice 204 utilizing the void created in the unbound region 210 and degrade the first layer 212 throughout the open-cell lattice 204 such that most, if not all, of the first layer 212 is removed at a similar, if not the same, rate. For example, most of, if not all, of the first layer 212 and/or struts 214 can be removed prior to degrading a surface of the part 202 covered by a region of the first layer 212. When the first layer 212 and/or struts 214 are removed, an exterior surface of the part 202 can be exposed. In various embodiments, the degradation can smooth the exterior surface of the part 202. In various embodiments, the open-cell lattice 204 comprises a non-uniform thickness. The non-uniform thickness can be adapted to selectively degrade a select region of the part 202 or selectively deposit material on the select region of the part 202 utilizing an electroplating process.

[0069] In various embodiments, the open-cell lattice 204 has a portion that does not comprise struts 214. For example, in embodiments without section 206f of frame 206, the portion of the open-cell lattice 204 that can be in communication with the surface 202a can consist of the first layer 212, which can protect the part 202 from degradation, but struts 214 may not be needed because the part 202 has already been manufactured prior to the portion of the open-cell lattice 204 that is in communication with surface 202a.

[0070] The open-cell lattice 204 can be configured based on properties of the selected electrolyte (e.g., rate of chemical degradation, conductivity, concentration, viscosity) and/or properties of the part 202. In various embodiments, the thickness of the open-cell lattice 204 can be adjusted to reduce the degradation time while providing sufficient restraint to the part 202 during manufacture. Additionally, the open-cell lattice 204 can be configured with sections that are thinner (e.g., reduced widths of the struts 214) than other sections of the open-cell lattice 204 so that the thinner sections are removed first.

[0071] In various embodiments, the open-cell lattice 204 can be configured such that upon degradation a distance between an anodic surface of the part 202 and cathodic surface of the frame 206 can be uniform throughout or varying in dimension throughout. In embodiments with varying distance dimensions, different current densities on the surface of the part 202 and/or open-cell lattice 204 can occur which result in different rates of degradation of material from the open-cell lattice 204 and/or part 202 and/or different thicknesses of material deposited on the part 202 by an electroplating process.

[0072] In various embodiments, the first layer 212 of the open-cell lattice 204 can have a thickness of at least 100 pm, such as, for example, at least 200 pm, at least 300 pm, at least 400 pm, at least 500 pm, at least 600 pm, at least 700 pm, at least 800 pm, at least 900 pm, at least 1 mm, or at least 1.5 mm. In various embodiments, the first layer 212 can have a thickness no greater than 2 mm, such as, for example, no greater than 1.5 mm, no greater than 1 mm, no greater than 900 pm, no greater than 800 pm, no greater than 700 pm, no greater than 600 pm, no greater than 500 pm, no greater than 400 pm, no greater than 300 pm, or no greater than 200 pm. In various embodiments, the first layer 212 can have a thickness in the range of 100 pm to 2 mm, such as, for example, 100 pm to 1 mm, 100 pm to 500 pm, or 200 pm to 900 pm.

[0073] The struts 214, for example, can extend between the first layer 212 and the second layer 216 or the first layer 212 and the frame 206. The struts 214 can be adapted to restrain the part 202. In various embodiments, the struts 214 extend radially from the first layer 212. The struts 214 can have the same width and/or length throughout the open-cell lattice 204 or have different widths and/or lengths. The electrolyte can flow throughout the open-cell lattice 204 utilizing the unbound region 210 and degrade the struts 214 throughout the open cell lattice 204. Upon removal of the struts 214 and/or first layer 212, the part 202 can be freed from the structure 200. For example, the part 202 may not be attached to the frame 206 after removal of the open-cell lattice 204. In various embodiments, the keyways 220 may have to be removed in order to free the part 202 from the structure 200 after removal of the struts 214. In various embodiments, each one of the struts 214 can be attached to a single build layer of the part 202. In various embodiments, each one of the struts 214 can be attached to a plurality of build layers of the part 202. Thus, the quantity of build layers that each one of stmts 214 comprises or that each one of stmts 214 attaches to in the part 202 and/or the frame 206 should not be considered limiting.

[0074] In various embodiments, the stmts 214 can comprise a radial extension connected to an outer surface of the part 202 such that the radial extension extends in a generally outward direction from the outer surface of the part 202.

[0075] In various embodiments, the stmts 214 can have a width (e.g., a diameter) of at least 100 pm, such as, for example, at least 200 pm, at least 300 pm, at least 400 pm, at least 500 pm, at least 600 pm, at least 700 pm, at least 800 pm, at least 900 pm, at least 1 mm, or at least 1.5 mm. In various embodiments, the stmts 214 can have a width no greater than 2 mm, such as, for example, no greater than 1.5 mm, no greater than 1 mm, no greater than 900 pm, no greater than 800 pm, no greater than 700 pm, no greater than 600 pm, no greater than 500 pm, no greater than 400 pm, no greater than 300 pm, or no greater than 200 pm. In various embodiments, the stmts 214 can have a width in the range of 100 pm to 2 mm, such as, for example, 100 pm to 500 pm, 100 pm to 1.5 mm, or 200 pm to 900 pm. In various embodiments, the width of the stmts 214 is proportional to the expected shrinkage at the point where the respective stmt 214 attaches to the part 202 via the first layer 212. In various embodiments, the width of the stmts 214 is proportional to the thickness of the part 202 at the point where the respective stmt 214 attaches to the part 202 via the first layer 212.

[0076] In various embodiments, the stmts 214 can have a length (e.g., a distance from an attachment point on the first layer 212 to an attachment point on the second layer 216 or the frame 206) of at least 100 pm, such as, for example, at least 200 pm, at least 300 pm, at least 400 pm, at least 500 pm, at least 600 pm, at least 700 pm, at least 800 pm, at least 900 pm, or at least 2 mm. In various embodiment, the stmts 214 can have a length of no greater than 10 mm, such as, for example, no greater than 2 mm, no greater than 900 pm, no greater than 800 pm, no greater than 700 pm, no greater than 600 pm, no greater than 500 pm, no greater than 400 pm, no greater than 300 pm, or no greater than 200 pm. In various embodiments, the stmts 214 can have a length in the range of 100 pm to 10 mm, such as, for example,

100 pm to 5 mm, 100 pm to 500 pm, or 200 pm to 900 pm.

[0077] As shown in FIG. 3A, the stmts 214 can comprise a shape having a section with a reduced width. For example, a first section 214a of the stmts 214 adjacent to the first layer 212 can have a first width; a third section 214c of the stmts 214 adjacent to the second layer can have a third width; and a second section 214b of the struts 214 between the first section 214a and the third section 214c can have a second width. The second width can be smaller than the first width and the third width. The second section 214b of the struts 214 can degrade faster (e.g., heat faster, chemically degrade faster, electrochemically degrade faster) than the first section 2l4a and the third section 2l4c of the struts 214. In various

embodiments, the shape of the struts 214 can comprise an hourglass shape.

[0078] The size, orientation, length, width, and shape of the struts 214 can vary and, thus, the illustrations of struts 214 in FIGs. 3A-D should not be considered limiting. For example, the open-cell lattice 204 can be configured as at least one of a diamond lattice, a tetrahedral lattice, a dodecahedron lattice, an octet-truss lattice, a cubic lattice, a tetrakai decahedron lattice, a truncated cuboctahedron lattice, a gyroid lattice, a helical lattice, a voronoi patterned lattice, a hexagonal lattice, and a Schwartz lattice. The configuration of the open-cell lattice 204 can be selected based on, for example, a desired restraint strength, a desired interior open volume, and/or degradability. In some embodiments, only a portion of the part 202 requires restraint, so at different part portions different lattice structures can be utilized, providing tailored support for unique part requirements. A structure of the open-cell lattice 204 can be at least one of geometric, non-geometric, and asymmetric in various portions, based on at least one of a specification, a dimension, and/or a build orientation of the part 202.

[0079] The loose powder can be removed from the unbound region 210 in FIG. 3 A and a void can be formed. In various embodiments, the part 202 can be configured as anode and connected to the positive terminal 222b of a DC voltage source (not shown in FIGs. 3 A-D). For example, a contact can electrically connect the part 202 to the positive terminal 222b.

The contact can comprise a keyway, a support section, and a secondary electrode. In embodiments where the contact comprises a keyway, the contact keyway may comprise an outer non-conductive material and an inner electrode such that the inner electrode is electrically isolated from sections of the frame 206 that the contact key way interacts with.

The inner electrode can contact the part 202 when the contact keyway is inserted into a slot.

In embodiments where the contact comprises a support section, the support section can comprise, for example, a section of the frame (e.g., a section of the frame 206 directly attached to the part 202) and a mounting structure connecting a section of the frame 206 to the part 202. In embodiments where the contact comprises a secondary electrode, the second electrode may be placed in direct contact with the part and/or a section of the frame 206 directly attached to the part 202.

[0080] In various embodiments, the frame 206 can be configured as a cathode and connected to the negative terminal 222a of the DC electrical power source. For example, a secondary electrode can electrically connect the frame 202 to the negative terminal 222a.

The section 206f shown in FIGs. 3 A-D is for illustration purposes only, and the principles of operation for degradation can apply to the other sections 206a-e of the frame 206.

[0081] The electrolyte can be added to unbound region 210 and a voltage potential can be created between the part 202 and the frame 206 (sixth section 206f as shown in FIGs. 3 A-D). Electrical communication between the part 202 and frame 206 is facilitated by the open-cell lattice 204 (e.g., struts 214) until the degradation of the open-cell lattice breaks the struts 214 and forms discontinuities in the struts 214. For example, the voltage potential can create an electric current through the struts 214 (e.g., short circuit) suitable to degrade the open-cell lattice 204 through ohmic heating. In various embodiments, the electrolyte can chemically degrade the open-cell lattice 204 and the ohmic heating increases the reaction rate of degradation and/or initiates the degradation reaction. The voltage potential can be based on the material composition of the open-cell lattice 204, the geometric configuration of the open cell lattice 204, and the electrolyte.

[0082] In a DC system, the voltage potential can be at least 1 volt DC (VDC), at least 5 VDC, at least 10 VDC, at least 12 VDC, at least 15 VDC, at least 24 VDC, or at least 48 VDC. In a DC system, the voltage potential can be no greater than 100 VDC, no greater than 48 VDC, no greater than 24 VDC, no greater than 12 VDC, no greater than 10 VDC, or no greater than 5 VDC. The voltage potential can be in a voltage range of 1 VDC to

100 VDC, such as, for example, 5 VDC to 50 VDC, or 5 VDC to 24 VDC.

[0083] In an AC system, the voltage potential can be at least 1 volt AC (VAC), at least 5 VAC, at least 10 VAC, at least 120 VAC, or at least 240 VAC. In an AC system, the voltage potential can be no greater than 300 VAC, no greater than 240 VAC, no greater than 120 VAC, no greater than 10 VAC, or no greater than 5 VAC. In an AC system, the voltage potential can be in a voltage range of 1 VAC to 300 VAC, such as, for example, 10 VAC to 240 VAC, or 120 VAC to 240 VAC. [0084] The electric current through the struts 214 can be controlled to facilitate the degradation of the struts 214. For example, the electric current can be controlled according to the size and compositions of the struts 214. The electric current through the struts 214 can be at least 0.1 ampere (A), such as, for example, at least 1 A, at least 10 A, at least 50 A, at least 100 A, at least 200 A, or at least 500 A. The electric current through the strut can be no greater than 1,000 A, such as, for example, no greater than 500 A, no greater than 200 A, no greater than 100 A, no greater than 50 A, no greater than 10 A, or no greater than 1 A. The size of and composition of the strut can affect the electric current required to degrade the open-cell lattice. For example, a strut comprising copper and having a width of 2 mm may be subjected to 0.1 A to 240 A of electric current, and a strut comprising copper and having a width of 100 pm may be subjected to 0.1 A to 2.5 A of electric current. A strut comprising aluminum and having a width of 2 mm may be subjected to 0.1 A to 180 A of electric current, and a strut comprising aluminum having a width of 0.1 mm may be subjected to 0.1 A to 1.9 A of electric current. A strut comprising iron and having a width of 2 mm may be subjected to 0.1 A to 70 A of electric current, and a strut comprising iron having a width of 0.1 mm may be subjected to 0.1 A to 0.8 A of electric current. A strut comprising tin and having a width of 2 mm may be subjected to 0.1 A to 40 A of electric current, and a strut comprising tin and having a width of 0.1 mm may be subjected to 0.1 A to 0.4 A of electric current.

[0085] After subjecting the struts to the electric current for a period of time, the struts 214 can be degraded as shown in FIG. 3B. In various embodiments, the second section 214b of the struts 214 can degrade faster than the first section 214a and the third section 214c of the struts 214 due to the reduced width of the second section 2l4b (e.g., increased heating in the reduced width, less material to remove in the second section 214b).

[0086] As shown in FIG. 3C, as the degradation of the struts 214 continues, the struts 214 can break and form discontinuities and at least partially electrically isolate the part 202 from the frame 206 such that electric current flows through the electrolyte and a current density on the surface of the part 202 and/or open-cell lattice 204 remaining on the part 202 is formed. Open-cell lattice 204 remaining on the part 202 after a discontinuity is formed in the struts 214 can become anodic and electrochemically degrade. For example, the open-cell lattice 204 remaining on the part 202 can dissolve into the electrolyte and, in various embodiments, accumulate on the frame 206. [0087] The current density can be suitable to electrochemically degrade the remaining open-cell lattice 204 based on the material composition of the open-cell lattice 204, the geometric configuration of the open-cell lattice 204, and the electrolyte. In various embodiments, the current density can facilitate electropolishing, electroplating, and/or anodizing of the part 202. The current density can be at least 0.1 A/square decimeter (dm2), such as, for example, at least 1 A/dm2, at least 10 A/dm2, at least 50 A/dm2, at least 100 A/dm2, at least 1,000 A/dm2, at least 10,000 A/dm2, or at least 50,000 A/dm2. The current density can be no greater than 100,000 A/dm2, such as, for example, no greater than 50,000 A/dm2, no greater than 10,000 A/dm2, no greater than 1,000 A/dm2, no greater than 100 A/dm2, no greater than 50 A/dm2, no greater than 10 A/dm2, or no greater than

1 A/dm2. The current density can be in a range of 0.1 A/dm2 to 100,000 A/dm2, such as, for example, 1 A/dm2 to 50,000 A/dm2, or 1,000 A/dm2 to 50,000 A/dm2.

[0088] The bulk temperature of the electrolyte can affect the properties of the electrolyte (e.g., rate of chemical degradation, conductivity, concentration, viscosity). For example, an increase in the bulk temperature of the electrolyte may lead to an increase in the rate of chemical degradation of the struts 214 and/or an increase in conductivity. The bulk temperature of the electrolyte can be at least 0 degrees Celsius (°C), such as, for example, at least l0°C, at least 20°C, at least 50°C, or at least l00°C. The bulk temperature of the electrolyte can be no greater than l50°C, such as, for example, no greater than l00°C, no greater than 50°C, or no greater than 20°C. The bulk temperature of the electrolyte can be in a range of 0°C to l50°C, such as, for example, l0°C to l50°C, or l0°C to l00°C. The local temperature of the electrolyte (e.g., portion of the electrolyte surrounding the open-cell lattice 204) may be different than the bulk temperature. For example, the local temperature of the electrolyte can be greater than the bulk temperature.

[0089] The electrolyte can be agitated to increase material removal from the open-cell lattice 204 and/or selectively remove material from the part 202. In various embodiments, the agitation can comprise, for example, stirring, aeration, and/or flowing electrolyte through the open-cell lattice (e.g., pumping). In various embodiments, aeration of the electrolyte can introduce oxygen into the electrolyte, and the oxygen can facilitate chemical reactions occurring at the surface of the part and/or the frame (e.g., anodizing).

[0090] Based on the material of the part 202, the electrolyte, current density, and temperature of the electrolyte can be selected. The Table below shows non-limiting embodiments of electrolyte system parameters (e.g., electrolyte, electrolyte solvent, current density, and electrolyte temperature) based on the material composition of the open-cell lattice 204.

Table

[0091] As shown in FIG. 3D, the open-cell lattice 204, including the struts 214, has been degraded. In various embodiments, a second voltage potential and electric current can be created between the part 202 and the frame 206. Creating the second voltage potential can comprise at least one of electropolishing the part 202 utilizing the electrolyte, electroplating the part 202 utilizing the electrolyte, and anodizing the part 202 utilizing the electrolyte.

[0092] FIG. 4 is a schematic representation of a front elevational view of a non-limiting embodiment of a powder bed additive manufacturing system 400 according to the present disclosure. The system 400 can be adapted to conduct at least one additive manufacturing process, such as, for example, BJAM, DMLS, SLM, SLS, or EBM. The system 400 can comprise a powder bed deposition region 432, including a powder bed deposition surface 434, a powder deposition module 436, and a joining module 438.

[0093] The powder bed deposition region 432 can be adapted to receive layers of metallic powder deposited by the powder deposition module 436. The metallic powder initially can be deposited on the powder bed deposition surface 434 and subsequently can be deposited on one or more powder layers previously deposited in the powder bed deposition region 432. In various embodiments, the powder bed deposition surface 434 is adapted to translate vertically to move the powder bed and facilitate deposition of further powder layers in the powder bed deposition region 432.

[0094] The powder deposition module 436 of the system 400 is adapted to deposit metallic powder in the powder bed deposition region 432. For example, the powder deposition module 436 can deposit a first layer 450a of metallic powder in the powder bed deposition region 432 and subsequently can deposit a second layer 450b of metallic powder in the powder bed deposition region 432 in communication with at least a portion of the underlying first layer 450a. In various embodiments, the powder deposition module 436 is adapted to deposit a plurality of additional layers of metallic powder, such as, for example, a third layer 450c, a fourth layer 450d, and a fifth layer 450e. The powder deposition module 436 can comprise at least one of a blade, a roller, a brush, and a hopper to facilitate deposition of powder layers.

[0095] The joining module 438 can be adapted to process metallic powder disposed in the powder bed deposition region 432 to thereby form the structure 200, which includes the part 202, an open-cell lattice 204, and a frame 206. For example, at least a selected region of the metallic powder in first layer 450a in the powder bed deposition region 432 can be affixed together by the joining module 438. In the first layer 450a, the joining module 438 may affix together the portions of the frame 206 present in the first layer 450a, if any; the sections of the bound region 208 of the open-cell lattice 204 present in the first layer 450a, if any; and the sections of the part 202 present in the first layer 450a, if any.

[0096] A selected region of the metallic powder in second layer 450b in the powder bed deposition region 432 can be affixed together by the joining module 438. For example, the joining module 438 may affix together the portions of the frame 206 present in the second layer 450b, if any; the sections of the bound region 208 in the open-cell lattice 204 present in the second layer 450b, if any; and the sections of the part 202 present in the second layer 450b, if any. Affixing metallic powder in the second layer 450b can bind and/or fuse the portions of the frame 206 present in the second layer 450b to the portions of the frame 206 present in the first layer 450a, if any; the sections of the bound region 208 in the open-cell lattice 204 present in the second layer 450b to the sections of the bound region 208 in the open-cell lattice 204 present in the first layer 450a, if any; and the sections of the part 202 present in the second layer 450b to the sections of the part 202 present in the first layer 450a, if any. For example, the second layer 450b can be at least partially affixed to the first layer 450a. In various embodiments, affixing the metallic powder can bind and/or fuse the sections of the respective component of the structure 200 in the second layer 450b to a different component in the structure 200 in the first layer 450a. This process can be repeated for each additional layer in the structure 200, such as layers 450c-e, until the structure 200 has been fully formed by the additive manufacturing process. [0097] As each layer 450a-e is being built, the joining module 438 can affix, in any order and in any combination, the sections of the part 202 present in the layer, the sections of the bound region 208 in the open-cell lattice 204 present in the layer, and the portions of the frame 206 present in the layer. In various embodiments, the joining module 438 affixes the metallic powder in the portions of the frame 206 present in the layer. Next, the joining module 438 affixes the metallic powder in sections of the open-cell lattice 204 present in the layer. Next, the joining module 438 affixes the metallic powder in sections of the part 202 present in the layer. Affixing the metallic powder in sections of the part 202 present in the layer last can provide enhanced restraint for the sections of the part 202 in the layer, which can minimize defects in a finished part.

[0098] Each layer 450a-e can be individually affixed by the joining module 438 or, alternatively, two or more powder layers 450a-e can be affixed simultaneously. For example, the powder deposition module 436 can deposit a single layer of metallic powder or a plurality of layers of metallic powder. Next, the joining module 438 can affix at least a selected region in the powder bed deposition region 432, including an exposed region. In various

embodiments, metallic powder in a selected region in the first layer 450a in the powder bed deposition region 432 can be affixed together by the joining module 438 prior to deposition of the metallic powder forming the second layer 450b. In various embodiments, metallic powder in at least the selected region of the first layer 450a and the selected region in the second layer 450b can be bound simultaneously. In various embodiments, the joining module 438 can affix the first layer 450a at least partially to the powder bed deposition surface 434. In various embodiments, there may be an unbound or unfused section 440 of metallic powder present in the layers 450a-e that is not within the structure 200.

[0099] The joining module 438 can be, for example, at least one of a binder deposition module and an energy source. The binder deposition module can be adapted to deposit a binder on an exposed layer of metallic powder in the powder bed deposition region 432 to bind the metallic powder in the selected region of the layer together and to metallic powder in an immediately adjacent underlying layer of metallic powder. For example, a selected region in the second layer 450b can be affixed to a selected region in the first layer 450a by a binder applied by the binder deposition module. In various embodiments, the binder can be a liquid binder selected from binders known in the art for use in binder jet additive manufacturing. [0100] In embodiments in which the joining module 438 is an energy source, the energy source, as is known the art, can be adapted to selectively sinter and/or melt metallic powder in a selected region of an exposed layer of metallic powder in the powder bed deposition region 432 to fuse the metallic powder in the selected region of the layer together and to an immediately adjacent underlying layer of metallic powder. For example, the selected region in the second layer 450b can be fused to the selected region in the first layer 450a by the energy source. The fusing of metallic powder to form the part 202 can be supported by the open-cell lattice 204. As the energy source melts the metallic powder, movement of the molten powder within the powder bed deposition region 432 can be limited by the open-cell lattice 204.

[0101] The energy source can comprise, for example, at least one of a laser module, an electron beam module, and a plasma torch module. A laser module can be adapted to direct a laser beam onto and heat at least a selected region of an exposed layer of metallic powder in the powder bed deposition region 432 to fuse metallic powder in the selected region together and/or to an immediately adjacent underlying layer of metallic powder. An electron beam module can be adapted to direct an electron beam onto and heat at least a selected region of an exposed layer of metallic powder in the powder bed reposition region 432 to fuse metallic powder in the selected region together and/or to an immediately adjacent underlying layer of powder. A plasma torch module can be adapted to direct plasma onto and heat at least a selected region of an exposed layer of metallic powder in the powder bed deposition region 432 to fuse the metallic powder in the selected region together and/or to an immediately adjacent underlying layer of metallic powder. For example, the selected region in the second layer 450b can be fused to the selected region in the first layer 450a by the laser module, electron beam module, and/or plasma torch module.

[0102] The sequence of depositing a layer or layers of metallic powder and affixing a selected region or regions of the layer or layers can be repeated as needed to produce layers of the structure 200, which includes metallic powder affixed together. The layer currently being built can exert, while cooling, a shear force on previously built layers of the structure 200, such as previously built layers of the part 202. The open-cell lattice 204 can transfer at least a portion of the shear force from the part 202 to the frame 206 and/or the powder deposition surface 434. The transfer of the shear forces out of the layers in the part 202 can reduce or minimize defects in the part 202. [0103] During the additive manufacturing process, the frame 206 can be manufactured so that layers built initially (e.g., layers 450a-b) are thicker than subsequently built layers (e.g., layers 450c-e), so as to enhance efficient transfer of shear stresses into the powder deposition surface 434. In various embodiments, the exterior surface of the frame 206 can be as smooth as possible to limit unnecessary stress concentrations in the structure 200. In some embodiments, a thickness of the frame 206 can be proportional to a thickness of the cross- sectional area of the respective build layer.

[0104] In various embodiments, the system 400 is provided with a void formation module (not shown) adapted to remove the loose powder in the unbound region 210 from the open cell lattice 204 to form a void. The void formation module can be adapted to receive the structure 200 and perform at least one operation on the structure 200, such as re-positioning, reorienting, shaking, vibrating, vacuuming, and blowing a pressurized gas through the unbound region 210 of the open-cell lattice 204. For example, the void formation module can comprise at least one of a tumbler, a shaker, a vibration table, a vacuum, and a compressor.

[0105] Referring to FIG. 5, a schematic representation of a front elevational view of a non-limiting embodiment of a removal module 500 according to the present disclosure is provided. The removal module 500 can be adapted to provide an electrolyte 542 (e.g., liquid electrolyte) to the unbound region 210 of the open-cell lattice 204 in the structure 200. For example, the removal module 500 can comprise at least one of a vessel 544 and a pump (not shown). As illustrated, the vessel 544 can be adapted to receive the electrolyte 542 and to at least partially submerge the structure 200 comprising the part 202, the open-cell lattice 204, and the frame 206 in the electrolyte. Upon submerging the structure 200 in the electrolyte, the unbound region 210 of the open-cell lattice 204 can fill with the electrolyte.

[0106] An electrical power source 522 can be in electrical communication with the frame 206 and the part 202. The electrical power source 522 can comprise, for example, an AC electrical power source and a DC electrical power source. In various embodiments where the electrical power source 522 comprises a DC electrical power source, the frame 206 can be in electrical communication with the negative terminal of the DC electrical power source, and the part 202 can be in electrical communication with the positive terminal of the DC electrical power source. The electrical power source 522 can be adapted to degrade the open cell lattice utilizing at least one of ohmic heating and electrochemical degradation. The electrical power source 522 can be adapted to pass an electric current through the open-cell lattice and heat the open-cell lattice. The electrical power source 522 can be adapted to pass an electric current through the electrolyte to facilitate electrochemical degradation of the open-cell lattice 204 and/or electropolishing, electroplating, and/or anodizing of the part 202.

[0107] After the open-cell lattice 204 has been degraded, the part 202 can be removed from the structure 200. For example, the keyways 220 can be removed and the sections 206e-f of the frame 206 can fall away from the part 200.

[0108] In other embodiments, the pump can be adapted to pass the electrolyte through the void formed by removing loose powder form the unbound region 210 of the open-cell lattice 204. For example, the structure 200 may comprise an inlet and an outlet suitable to transport the electrolyte 542. The electrolyte 542 can be pumped into the inlet, flow through the open cell lattice 204, chemically degrade the open-cell lattice 204, and exit through the outlet.

[0109] In various embodiments, the removal module 500 can comprise an additional component, such as, for example, at least one of a heater, a recirculation pump, a vibratory module, and other devices suitable to enhance the degradation of the open-cell lattice 204.

[0110] The part 202 can comprise at least one material selected from the group consisting of titanium, titanium alloy, aluminum, aluminum alloy, nickel, nickel alloy, iron particles, iron alloy, cobalt, cobalt alloy, copper, copper alloy, molybdenum, molybdenum alloy, magnesium, magnesium alloy, tantalum, tantalum alloy, chromium, chromium alloy, tungsten, tungsten alloy, zinc, zinc alloy, silver, silver alloy, chromium, chromium alloy, tin, tin alloy, gold, gold alloy, platinum, platinum alloy, zirconium, and zirconium alloy.

[0111] The parts described herein may be manufactured via any appropriate additive manufacturing technique described in ASTM F2792-l2a. In one embodiment, an additive manufacturing process includes depositing successive layers of powder and then selectively melting and/or sintering the powder to create, layer-by-layer, a part. In one embodiment, a powder bed is used to create a part such as, for example, a tailored alloy part and/or a unique structure unachievable through traditional manufacturing techniques (e.g., without excessive post-processing machining).

[0112] Non-limiting examples of additive manufacturing processes useful in producing parts from feedstocks include, for example, BJAM, DMLS, SLM, SLS, and EBM, among others. In one embodiment, an additive manufacturing process uses an EOSINT M 280 Direct Metal Laser Sintering (DMLS) additive manufacturing system, or comparable system, available from EOS GmbH (Robert-Stirling-Ring 1, 82152 Krailling/Munich, Germany). Additive manufacturing techniques (e.g., when utilizing metallic feedstocks) may facilitate the selective heating of powder above the liquidus temperature of the powder, thereby forming a molten pool followed by rapid solidification of the molten pool.

[0113] Any suitable feedstocks may be used, including powder, a wire, a sheet, and combinations thereof. In various embodiments, the feedstock may be, for example, metallic feedstocks (e.g., with additives to promote various properties such as, for example, grain refiners and/or ceramic materials), polymeric feedstocks (e.g., plastic feedstocks), and ceramic feedstocks. In certain embodiments, the wire can comprise a ribbon and/or a tube. The metallic feedstocks can be at least one of titanium, titanium alloy, aluminum, aluminum alloy, nickel, nickel alloy, iron, iron alloy, cobalt, cobalt alloy, copper, copper alloy, molybdenum, molybdenum alloy, magnesium, magnesium alloy, tantalum, tantalum alloy, tungsten, tungsten alloy, zinc, zinc alloy, silver, silver alloy, chromium, chromium alloy, tin, tin alloy, gold, gold alloy, platinum, platinum alloy, zirconium, and zirconium alloy. In certain embodiments, reagent-based feedstock materials which form polymeric parts can be used as feedstock.

[0114] As used herein,“aluminum alloy” means a metal alloy having aluminum as the predominant alloying element. Similar definitions apply to the other corresponding alloys referenced herein (e.g., titanium alloy means a titanium alloy having titanium as the predominant alloying element).

[0115] In one approach, an additive manufacturing process comprises (a) dispersing a feedstock (e.g., powder in a powder bed), (b) selectively heating a portion of the powder (e.g., via an energy source) to a temperature above the liquidus temperature of the powder,

(c) forming a molten pool and (d) cooling the molten pool at a cooling rate of at least l000°C per second, such as, for example, at least l0,000°C per second, at least l00,000°C per second, or at least l,000,000°C per second. Steps (a)-(d) may be repeated as necessary until the additively manufactured part is completed.

[0116] In another approach, an additive manufacturing process comprises (a) dispersing a feedstock (e.g., metallic powder) in a deposition region, (b) selectively binder jetting the feedstock, and (c) repeating steps (a)-(b), thereby producing a final additively manufactured part (e.g., including optionally heating to burn off binder and form a green form, followed by sintering to form the additively manufactured part).

[0117] In another approach, electron beam or plasma arc techniques are utilized to produce at least a portion of the additively manufactured part. Electron beam techniques may facilitate production of larger parts than readily produced via laser additive manufacturing techniques. An illustrative example provides feeding a wire to the wire feeder portion of an electron beam gun. The wire may comprise a metallic feedstock. The electron beam heats the wire above the liquidus point of the metallic feedstock and deposits the molten pool in a deposition region. Thereafter, rapid solidification of the molten pool to form the deposited material occurs.

[0118] Production and Processing

[0119] In some embodiments, the additively manufactured part may be subject to any appropriate dissolving (e.g., includes homogenization), working and/or precipitation hardening steps. If employed, the dissolving and/or the working steps may be conducted on an intermediate form of the additively manufactured part and/or may be conducted on a final form of the additively manufactured part. If employed, the precipitation hardening step is generally conducted relative to the final form of the additively manufactured part.

[0120] After or during production, an additively manufactured part may be deformed (e.g., by one or more of rolling, extruding, forging, stretching, compressing). The final deformed product may realize, for instance, improved properties due to the tailored regions and thermo- mechanical processing of the final deformed part. Thus, in some embodiments, the final part is a wrought part, the word“wrought” referring to the working (hot working and/or cold working) of the additively manufactured part, wherein the working occurs relative to an intermediate and/or final form of the additively manufactured part. In other approaches, the final part is a non-wrought product, i.e., is not worked during or after the additive

manufacturing process. In these non-wrought product embodiments, any appropriate number of dissolving and precipitating steps may still be utilized.

[0121] Product Applications [0122] The resulting additively manufactured parts made in accordance with the systems and methods described herein may be used in a variety of product applications such as, commercial end-uses in industrial applications, in consumer applications (e.g., consumer electronics and/or appliances), or in other areas. For example, the additively manufactured parts can be utilized in at least one of the aerospace field (e.g., aerospace component), automotive field (e.g., automotive component), transportation field (e.g., transportation component), or building and construction field (e.g., building component or construction component). In certain embodiments, the additively manufactured parts can be configured as at least one of an aerospace component, an automotive component, a transportation component, and a building and construction component.

[0123] In one embodiment, an additively manufactured part can be utilized in an elevated temperature application, such as in an aerospace or automotive vehicle. In one embodiment, an additively manufactured part can be utilized as an engine component in an aerospace vehicle (e.g., in the form of a blade, such as a compressor blade incorporated into the engine). In another embodiment, an additively manufactured part can be used as a heat exchanger for the engine of the aerospace vehicle. The aerospace vehicle including the engine component / heat exchanger may subsequently be operated. In one embodiment, an additively

manufactured part can be an automotive engine component. The automotive vehicle including an automotive component (e.g., engine component) may subsequently be operated. For instance, the additively manufactured part may be used as a turbo charger component (e.g., a compressor wheel of a turbo charger, where elevated temperatures may be realized due to recycling engine exhaust back through the turbo charger), and the automotive vehicle including the turbo charger component may be operated. In another embodiment, an additively manufactured part may be used as a blade in a land based (stationary) turbine for electrical power generation, and the land-based turbine included the additively manufactured part may be operated to facilitate electrical power generation. In some embodiments, an additively manufactured part can be utilized in defense applications, such as in body armor, and armed vehicles (e.g., armor plating). In other embodiments, the additively manufactured part can be utilized in consumer electronic applications, such as in consumer electronics, such as, laptop computer cases, battery cases, cell phones, cameras, mobile music players, handheld devices, computers, televisions, microwaves, cookware, washers/dryers, refrigerators, and sporting goods, among others. [0124] In another aspect, an additively manufactured part can be utilized in a structural application, such as, for example, an aerospace structural application and an automotive structural application. For instance, the additively manufactured part may be formed into various aerospace structural components, including floor beams, seat rails, fuselage framing, bulkheads, spars, ribs, longerons, and brackets, among others. In another embodiment, the additively manufactured part can be utilized in an automotive structural application. For instance, the additively manufactured part can be formed into various automotive structural components including nodes of space frames, shock towers, and subframes, among others. In one embodiment, the additively manufactured part can be a body -in-white automotive product.

[0125] In another aspect, the additively manufactured part can be utilized in an industrial engineering application. For instance, the additively manufactured part or products may be formed into various industrial engineering products, such as tread-plate, tool boxes, bolting decks, bridge decks, and ramps, among others.

[0126] Various aspects of the invention according to the present disclosure include, but are not limited to, the aspects listed in the following numbered clauses:

1. A method comprising:

forming a part configured as a first electrode from metallic powder in a powder bed deposition region of an additive manufacturing apparatus, wherein the part is restrained in the powder bed deposition region by an open-cell lattice formed from the metallic powder and comprising an unbound region and a bound region, wherein the unbound region is adapted to form a void;

forming a frame configured as a second electrode from the metallic powder in the powder bed deposition region of the additive manufacturing apparatus, wherein the frame is in communication with and is adapted to restrain the open-cell lattice; and creating a voltage potential between the part as the first electrode and the frame as the second electrode and degrading the open-cell lattice utilizing at least one of ohmic heating and electrochemical degradation.

2. The method of clause 1, wherein forming a part configured as a first electrode further comprises: connecting a contact in electrical communication with the part, wherein the contact is at least one of a keyway, a support section, and an electrode. The method of any one of clauses 1-2, wherein degrading the open-cell lattice comprises passing an electric current through the open-cell lattice and heating the open-cell lattice. The method of any one of clauses 1-3, wherein the frame comprises a slot and the method further comprises, prior to creating the voltage potential:

inserting a key way into the slot and thereby restraining movement of the frame. The method of clause 4, further comprising:

removing the keyway from the slot after degrading the open-cell lattice. The method of any one of clauses 4-5, wherein the keyway comprises a non- conductive material. The method of any one of clauses 4-6, wherein the key way comprises a third electrode. The method of any one of clauses 1-7, wherein the open-cell lattice comprises struts extending from the frame to the part, and wherein degrading the open-cell lattice comprises breaking the struts to create a discontinuity in the struts. The method of any one of clauses 1-8, wherein the first electrode is an anode and the second electrode is a cathode. The method of clauses 1-8, further comprising creating a second voltage potential between the part and the frame after degrading the open-cell lattice. The method of clause 10, wherein creating the second voltage potential comprises at least one of electropolishing the part utilizing the electrolyte, electroplating the part utilizing the electrolyte, and anodizing the part utilizing the electrolyte. The method of any one of clauses 1-11, further comprising: removing powder from the unbound region from the lattice structure to form the void. The method of any one of clauses 1-12, wherein the void is capable of receiving an electrolyte. The method of clause 13, further comprising introducing the electrolyte into the void. The method of clause 14, wherein introducing the electrolyte into the void comprises at least one of pumping the electrolyte into the void and submerging the part and the open-cell lattice in a volume of the electrolyte. The method of any one of clauses 13-15, wherein the electrolyte is at least one compound selected from the group consisting of sulfuric acid, hydrofluoric acid, chromic acid, sodium carbonate, trisodium phosphate, sodium nitrate, hydrochloric acid, phosphoric acid, acetic acid, perchloric acid, ammonium bifluoride, fluoroboric acid, aluminum chloride, zinc chloride, sodium chloride, potassium chloride, sodium nitrate, sodium chlorate, boric acid, sodium tripolyphosphate, sodium hydroxide, potassium hydroxide, choline hydroxide, tetramethylammonium hydroxide, and a trivalent metal salt. The method of any one of clauses 1-16, wherein the open-cell lattice comprises at least one structure selected from the group consisting of a diamond lattice, a tetrahedral lattice, a dodecahedron lattice, a octet-truss lattice, a cubic lattice, a tetrakai decahedron lattice, a truncated cuboctahedron lattice, a gyroid lattice, a helical lattice, a voronoi patterned lattice, a hexagonal lattice, and a Schwartz lattice. The method of any one of clauses 1-17, wherein the open-cell lattice comprises a strut having an hourglass shape. The method of any one of clauses 1-18, wherein the open-cell lattice comprises an interior open volume in the range of 20% to 90%. The method of any one of clauses 1-19, wherein the open-cell lattice comprises a strut size in the range of 100 pm to 2 mm. The method of any one of clauses 1-20, wherein the open-cell lattice contacts the frame and an exterior surface of the part. The method of any one of clauses 1-21, wherein the metallic powder comprises at least one material selected from the group consisting of titanium particles, titanium alloy particles, aluminum particles, aluminum alloy particles, nickel particles, nickel alloy particles, iron particles, iron alloy particles, cobalt particles, cobalt alloy particles, copper particles, copper alloy particles, molybdenum particles, molybdenum alloy particles, magnesium particles, magnesium alloy particles, tantalum particles, tantalum alloy particles, chromium particles, chromium alloy particles, tungsten particles, tungsten alloy particles, zinc particles, zinc alloy particles, silver particles, silver alloy particles, chromium particles, chromium alloy particles, tin particles, tin alloy particles, gold particles, gold alloy particles, platinum particles, platinum alloy particles, zirconium particles, and zirconium alloy particles. The method of any one of clauses 1-22, wherein the metallic powder comprises a median particle size in a range of 50 nm to 325 pm. The method of any one of clauses 1-23, wherein the part is configured as at least one of an aerospace component, an automotive component, a transportation component, and a building and construction component. An article of manufacture produced by an additive manufacturing process, the article comprising:

an additively manufactured part configured as a first electrode;

an open-cell lattice in communication with at least a portion of the part and adapted to restrain the part, the open-cell lattice comprising an unbound region and a bound region, wherein the unbound region is adapted to form a void; and

a frame in communication with and adapted to restrain the open-cell lattice, wherein the frame is configured as a second electrode and is disposed in a position in relation to the part adapted for establishing a voltage potential between the frame and the part. The article of clause 25, further comprising: a contact in electrical communication with the part, wherein the contact is at least one of a keyway, a support section, and an electrode. The article of any one of clauses 25-26, further comprising:

an electrical power source in electrical communication with the part and the frame, the electrical power source adapted to degrade the open-cell lattice utilizing at least one of ohmic heating and electrochemical degradation. The article of clause 27, wherein the electrical power source adapted to degrade the open-cell lattice comprises the electrical power source adapted to pass an electric current through the open-cell lattice and heat the open-cell lattice. The article of any one of clauses 25-28, further comprising a slot disposed in the frame, wherein the slot is configured to receive a keyway adapted to restrain the frame. The article of clause 29, wherein the keyway comprises a non-conductive material. The article of any one of clauses 29-30, wherein the keyway comprises a third electrode. The article of any one of clauses 25-31, wherein the first electrode is an anode and the second electrode is a cathode. The article of any one of clauses 25-32, wherein the void is adapted to receive an electrolyte. The article of clause 33, wherein the electrolyte is at least one compound selected from the group consisting of sulfuric acid, hydrofluoric acid, chromic acid, sodium carbonate, trisodium phosphate, sodium nitrate, hydrochloric acid, phosphoric acid, acetic acid, perchloric acid, ammonium bifluoride, fluoroboric acid, aluminum chloride, zinc chloride, sodium chloride, potassium chloride, sodium nitrate, sodium chlorate, boric acid, sodium tripolyphosphate, sodium hydroxide, potassium hydroxide, choline hydroxide, tetramethylammonium hydroxide, and a trivalent metal salt. The article of any one of clauses 25-34, wherein the open-cell lattice comprises at least one structure selected from the group consisting of a diamond lattice, a tetrahedral lattice, a dodecahedron lattice, a octet-truss lattice, a cubic lattice, a tetrakai decahedron lattice, a truncated cuboctahedron lattice, a gyroid lattice, a helical lattice, a voronoi patterned lattice, a hexagonal lattice, and a Schwartz lattice. The article of any one of clauses 25-35, wherein the open-cell lattice comprises a strut having an hourglass shape. The article of any one of clauses 25-36, wherein the open-cell lattice comprises an interior open volume in the range of 20% to 90%. The article of any one of clauses 25-37, wherein the open-cell lattice comprises a strut size in the range of 100 pm to 2 mm. The article of any one of clauses 25-38, wherein the open-cell lattice contacts the frame and an exterior surface of the part. The article of any one of clauses 25-39, wherein the open-cell lattice has a

composition adapted to degrade to expose an exterior surface of the part. The article of any one of clauses 25-40, wherein the open-cell lattice comprises at least one of a uniform thickness adapted to degrade prior to degradation of the part and a non-uniform thickness adapted to selectively degrade a select region of the part or selectively deposit material on the select region of the part utilizing an

electroplating process.. The article of any one of clauses 25-41, wherein the part comprises at least one material selected from the group consisting of titanium, titanium alloy, aluminum, aluminum alloy, nickel, nickel alloy, iron particles, iron alloy, cobalt, cobalt alloy, copper, copper alloy, molybdenum, molybdenum alloy, magnesium, magnesium alloy, tantalum, tantalum alloy, chromium, chromium alloy, tungsten, tungsten alloy, zinc, zinc alloy, silver, silver alloy, chromium, chromium alloy, tin, tin alloy, gold, gold alloy, platinum, platinum alloy, zirconium, and zirconium alloy. The article of any one of clauses 25-42, wherein the part is configured as at least one of an aerospace component, an automotive component, a transportation component, and a building and construction component. A powder bed additive manufacturing system comprising:

a powder bed deposition region adapted to receive layers of metallic powder and comprising a powder bed deposition surface;

a powder deposition module adapted to dispose layers of metallic powder in the powder bed deposition region;

a joining module adapted to process metallic powder disposed in the powder bed deposition region to thereby form a part, an open-cell lattice, and a frame from the metallic powder, wherein the open-cell lattice is in communication with at least a portion of the part and is adapted to restrain the part in the powder bed deposition region, and wherein the open-cell lattice comprises an unbound region and a bound region, the unbound region adapted to form a void; and

an electrical power source adapted to degrade the open-cell lattice utilizing at least one of ohmic heating and electrochemical degradation. The system of clause 44, wherein the electrical power source adapted to degrade the open-cell lattice comprises the electrical power source adapted to pass an electric current through the open-cell lattice and heat the open-cell lattice. The system of any one of clauses 44-45, wherein the joining module comprises at least one of a binder deposition module, a laser module, an electron beam module, and a plasma torch. The system of any one of clauses 44-46, wherein the powder deposition module comprises at least one of a blade, a roller, a brush, and a hopper. The system of any one of clauses 44-47, further comprising a removal module adapted to introduce an electrolyte into the void, the removal module comprising at least one of a vessel and a pump, wherein the vessel is adapted to receive the electrolyte and to submerge the part, and wherein the pump is adapted to introduce the electrolyte into the void. The system of any one of clauses 44-48, further comprising a void formation module adapted to remove powder from the unbound region from the open-cell lattice structure to form the void. The system of any one of clauses 44-49, wherein the void is adapted to receive an electrolyte. The system of clause 50, wherein the electrolyte is at least one compound selected from the group consisting of sulfuric acid, hydrofluoric acid, chromic acid, sodium carbonate, trisodium phosphate, sodium nitrate, hydrochloric acid, phosphoric acid, acetic acid, perchloric acid, ammonium bifluoride, fluoroboric acid, aluminum chloride, zinc chloride, sodium chloride, potassium chloride, sodium nitrate, sodium chlorate, boric acid, sodium tripolyphosphate, sodium hydroxide, potassium hydroxide, choline hydroxide, tetramethylammonium hydroxide, and a trivalent metal salt. The system of any one of clauses 44-51, wherein the open-cell lattice comprises at least one structure selected from the group consisting of a diamond lattice, a tetrahedral lattice, a dodecahedron lattice, a octet-truss lattice, a cubic lattice, a tetrakai decahedron lattice, a truncated cuboctahedron lattice, a gyroid lattice, a helical lattice, a voronoi patterned lattice, a hexagonal lattice, and a Schwartz lattice. The system of any one of clauses 44-52, wherein the open-cell lattice comprises an interior open volume in the range of 20% to 90%. The system of any one of clauses 44-53, wherein the open-cell lattice comprises a strut size in the range of 100 pm to 2 mm. The system of any one of clauses 44-54, wherein the open-cell lattice contacts an exterior surface of the part. The system of any one of clauses 44-55, wherein the open-cell lattice comprises at least one of a uniform thickness adapted to degrade prior to the degradation of the part and a non-uniform thickness adapted to selectively degrade a select region of the part or selectively deposit material on the select region of the part utilizing an

electroplating process. 57. The system of any one of clauses 44-56, wherein the part is configured as at least one of an aerospace component, an automotive component, a transportation component, and a building and construction component.

58. The system of any one of clauses 44-57, wherein the system is adapted to conduct at least one additive manufacturing process selected from binder jet additive

manufacturing, electron beam melting, direct metal laser sintering, selective laser melting, and selective laser sintering.

59. A method comprising:

providing a part configured as a first electrode from metallic powder in a powder bed deposition region of an additive manufacturing apparatus, wherein the part is restrained in the powder bed deposition region by an open-cell lattice formed from the metallic powder and comprising an unbound region and a bound region, wherein the unbound region is adapted to form a void;

providing a frame configured as a second electrode from the metallic powder in the powder bed deposition region of the additive manufacturing apparatus, wherein the frame is in communication with and is adapted to restrain the open-cell lattice; and directing a current from an anodic surface to a cathodic surface to remove at least a portion of the open-cell lattice, thereby providing a surface finished part.

[0127] One skilled in the art will recognize that the herein described methods, processes, systems, apparatus, components, devices, operations/actions, and objects, and the discussion accompanying them, are used as examples for the sake of conceptual clarity and that various configuration modifications are contemplated. Consequently, as used herein, the specific examples/embodiments set forth and the accompanying discussion are intended to be representative of their more general classes. In general, use of any specific exemplar is intended to be representative of its class, and the non-inclusion of specific components, devices, operations/actions, and objects should not be taken as limiting. While the present disclosure provides descriptions of various specific aspects for the purpose of illustrating various aspects of the present disclosure and/or its potential applications, it is understood that variations and modifications will occur to those skilled in the art. Accordingly, the invention or inventions described herein should be understood to be at least as broad as they are claimed and not as more narrowly defined by particular illustrative aspects provided herein.