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This technical report presents a novel manufacturing system that bridges traditional sheet‑metal fabrication and advanced additive manufacturing. The method converts generatively designed 3D geometries into layer‑specific sheet patterns containing both external contours and internal voids. Each sheet is produced from standard metal stock, incorporating integral raised‑and‑recessed alignment features that allow automated, self‑registering stacking. The assembled stack is consolidated through diffusion bonding or hot isostatic pressing to form a fully dense component with continuous internal channels With additional information and guideance
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MICHAEL BISWELL (2026) studied this question.
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