Concurrent, layer-by-layer powder and mold fabrication for multi-functional parts

A method of making a part using powder metallurgy and material extrusion, the method comprising:

• forming a mold of a first material by extruding the first material;
• depositing a second material into the mold, wherein multiple layers of the second material are deposited in the form of a powder;
• heating the mold and the second material within the mold, wherein, during the heating the mold is separated from the second material by melting, evaporating, burning, or combinations thereof of the first material;
• after the mold is separated from the second material, increasing pressure and temperature on the second material, wherein during the heating the second material is sintered;
• and
• obtaining a part, the part comprising the second material.

A method of making a part using powder metallurgy and material extrusion, the method comprising:

• extruding a first material into the form of a mold;
• depositing a particulate, in powder form, into the mold, wherein the particulate is a metal or ceramic powder;
• compacting the metal or ceramic powder within the mold;
• heating the mold and the metal or ceramic powder within the mold, wherein, during the heating the mold is separated from the metal or ceramic powder by melting, evaporating, burning, or combinations thereof of the first material, and wherein during the heating the metal or ceramic powder is sintered;
• and
• obtaining a part, the part comprising the sintered metal or ceramic powder.