Burners and additive manufacturing methods

1. A burner comprising:

a) burner body comprising:

1) a plurality of passageways;

2) a first major surface;

3) a plurality of ports at the first major surface, each port defined by an end of one of the passageways; and

4) a cooling chamber directly adjacent to three or more of the plurality of passageways, wherein the cooling chamber: is located closer to the first major surface of the burner body than to an opposing major surface of the burner body and/or surrounds three or more of the plurality of passageways;

 wherein the burner body comprises a plurality of layers of metal directly bonded to each other; and

b) at least one connector configured to supply at least a fuel and an oxidizer to the burner body.

2. The burner of claim 1 , wherein the burner body comprises a plurality of columns of grains of metal.

3. The burner of claim 1 , wherein the first major surface has 8 or more rows of ports.

4. The burner of claim 1 , wherein a pattern of the plurality of ports at the first major surface is asymmetrical.

5. The burner of claim 1 , wherein the metal comprises steel or a nickel alloy, preferably a nickel chromium alloy.

6. A method of making a burner body of claim 1 , the method comprising sequential steps:

a) a subprocess comprising sequentially:

i) depositing a layer of loose powder particles in a region, wherein the loose powder particles comprise metallic particles and wherein the layer of loose powder particles has substantially uniform thickness;

ii) selectively treating an area of the layer of loose powder particles with irradiation by a focused beam to bond metallic particles together;

b) independently carrying out step a) a plurality of times to generate a burner body comprising the bonded powder particles and remaining loose powder particles, wherein in each step a), the loose powder particles are independently selected; and

c) separating substantially all of the remaining loose powder particles from the burner body.

7. A non-transitory machine-readable medium having data representing a three-dimensional model of a burner body, when accessed by one or more processors interfacing with a 3D printer, cause the 3D printer to create the burner body comprising:

1) a plurality of passageways;

2) a first major surface;

3) a plurality of ports at the first major surface, each port defined by an end of one of the passageways; and

4) a cooling chamber directly adjacent to three or more of the plurality of passageways, wherein the cooling chamber: is located closer to the first major surface of the burner body than to an opposing major surface of the burner body and/or surrounds three or more of the plurality of passageways;

 wherein the burner body comprises a plurality of layers of metal directly bonded to each other.

8. A method, comprising:

retrieving, from a non-transitory machine-readable medium, data representing a 3D model of a burner body, the burner body comprising:

1) a plurality of passageways;

2) a first major surface;

3) a plurality of ports at the first major surface, each port defined by an end of one of the passageways; and

4) a cooling chamber directly adjacent to three or more of the plurality of passageways, wherein the cooling chamber: is located closer to the first major surface of the burner body than to an opposing major surface of the burner body and/or surrounds three or more of the plurality of passageways;

 wherein the burner body comprises a plurality of layers of metal directly bonded to each other;

executing, by one or more processors, a 3D printing application interfacing with a manufacturing device using the data; and

generating, by the manufacturing device, a physical object of the burner body.

9. A burner body generated using the method of claim 8 .

10. A method of forming a burner body, the method comprising:

receiving, by a manufacturing device having one or more processors, a digital object comprising data specifying a plurality of layers of a burner body, the burner body comprising:

1) a plurality of passageways;

2) a first major surface;

3) a plurality of ports at the first major surface, each port defined by an end of one of the passageways; and

4) a cooling chamber directly adjacent to three or more of the plurality of passageways, wherein the cooling chamber: is located closer to the first major surface of the burner body than to an opposing major surface of the burner body and/or surrounds three or more of the plurality of passageways;

 wherein the burner body comprises a plurality of layers of metal directly bonded to each other; and

generating, with the manufacturing device by an additive manufacturing process, the burner body based on the digital object.

11. A system comprising:

a display that displays a 3D model of a burner body; and

one or more processors that, in response to the 3D model selected by a user, cause a 3D printer to create a physical object of the burner body, the burner body comprising:

1) a plurality of passageways;

2) a first major surface;

3) a plurality of ports at the first major surface, each port defined by an end of one of the passageways; and

4) a cooling chamber directly adjacent to three or more of the plurality of passageways, wherein the cooling chamber: is located closer to the first major surface of the burner body than to an opposing major surface of the burner body and/or surrounds three or more of the plurality of passageways;

 wherein the burner body comprises a plurality of layers of metal directly bonded to each other.