Layered Sheet-Based Manufacturing for Complex Internal Geometries.

This work introduces a layered sheet‑based manufacturing method capable of producing complex internal geometries—such as branching channels, organic flow paths, and generative‑designed structures—that are difficult or uneconomical to fabricate using conventional machining or metal additive manufacturing. The process digitally slices a 3D component into patterned metal sheets, which are cut, stamped with self‑alignment features, stacked, and diffusion‑bonded into a monolithic part. This approach combines the geometric freedom of additive manufacturing with the scalability and material efficiency of sheet‑metal processing. It offers strong potential for compact cooling plates, heat exchangers, fluid manifolds, and conformal‑cooled tooling inserts, particularly where internal complexity provides measurable performance or economic value.