Method of joining additively manufactured components

Abstract

A method for producing a component from two or more sub-components includes the steps of: producing each of the sub-components using an additive manufacturing process in which a resin, which is radiant-energy-curable, is partially cured using a selective application of radiant energy, wherein each sub-component includes a joint surface in which the resin is partially cured which is cured to a lesser degree than the remainder of the respective sub-component, so as to leave the joint surfaces in a condition suitable for bonding; assembling the sub-components with their respective joint surfaces in mutual contact; and performing a secondary cure of the partially-cured resin at the joint surfaces using an application of radiant energy, so as to further cure the partially-cured resin and bond the sub-components to each other, thereby forming the component.

What is claimed is: 
     
         1 . A method for producing a component from two or more sub-components, comprising the steps of:
 producing each of the sub-components using an additive manufacturing process in which a resin, which is radiant-energy-curable, is partially cured using a selective application of radiant energy, wherein each sub-component includes a joint surface in which the resin is partially cured to a lesser degree than the remainder of the respective sub-component, so as to leave the joint surface in a condition suitable for bonding;   assembling the sub-components with their respective joint surfaces in mutual contact; and   performing a secondary cure of the partially-cured resin at the joint surfaces using an application of radiant energy, so as to further cure the partially-cured resin and bond the sub-components to each other, thereby forming the component.   
     
     
         2 . The method of  claim 1  wherein the secondary cure uses a nonselective application of radiant energy. 
     
     
         3 . The method of  claim 1  wherein the sub-components are produced sequentially. 
     
     
         4 . The method of  claim 1  wherein two or more of the sub-components are produced simultaneously in one additive manufacturing apparatus. 
     
     
         5 . The method of  claim 1  further including forming at least one mechanical joint feature at each joint surface. 
     
     
         6 . The method of  claim 1  wherein the secondary cure takes place in an oxygen-poor environment. 
     
     
         7 . The method of  claim 1  further comprising the step of disposing additional radiant-energy-curable resin between the joint surfaces, prior to performing the secondary cure. 
     
     
         8 . The method of  claim 1  wherein the resin includes a particulate material filler. 
     
     
         9 . The method of  claim 8  further comprising sintering the component to burn out the cured resin and consolidate the filler. 
     
     
         10 . The method of  claim 7  further comprising infiltrating a lower-melting-temperature material into the component during or after sintering. 
     
     
         11 . The method of  claim 1  wherein the selective application of radiant energy is applied by projecting a patterned image comprising a plurality of pixels. 
     
     
         12 . The method of  claim 11  wherein the patterned image is shifted during the application of radiant energy. 
     
     
         13 . The method of  claim 12  wherein additional radiant energy is applied by scanning at least one build beam over the surface of the resin. 
     
     
         14 . The method of  claim 1  wherein the selective application of radiant energy is applied by scanning a build beam over the surface of the resin. 
     
     
         15 . The method of  claim 1  wherein a joint surface is within a penetration distance of a secondary curing source. 
     
     
         16 . The method of  claim 15  further including restraining the sub-components in a fixture prior to the secondary cure.