Manufacturing method for a dual wall component

1. A method for forming a blade extending along a radial axis from a root to a tip, the method comprising:

forming a pressure side outer wall extending from a leading edge to a trailing edge;

forming a suction side outer wall extending from the leading edge to the trailing edge;

forming a first inner wall integral to and having a shape complimentary to the pressure side outer wall, wherein the first inner wall and the pressure side outer wall are separated by a first cavity; and

forming a second inner wall integral to and having a shape complimentary to the suction side outer wall, wherein the second inner wall and the suction side outer wall are separated by a second cavity, and wherein the second inner wall and the first inner wall are separated by a third cavity;

wherein each of the pressure and suction side outer walls, and the first and second inner walls includes a first thickness portion at a first radial position along the radial axis, and a second thickness portion at a second radial position along the radial axis, the second thickness portion being greater than the first thickness portion; and

wherein the pressure side outer wall, the suction side outer wall, the first inner wall and the second inner wall are formed by additive manufacturing and without using cores to form the first, second and third cavities.

2. The method of claim 1 , wherein, at the first radial position, the pressure side outer wall and the suction side outer wall have thicknesses less than 0.018″ (0.457 mm), and wherein, at the second radial position, the pressure side outer wall and the suction side outer wall have thicknesses between 0.040″ (1.02 mm) and 0.050″ (1.27 mm).

3. A dual wall component extending along a radial axis, the component comprising:

a first outer wall extending from a leading edge to a trailing edge;

a first inner wall integrally formed with the first outer wall and spaced from the first outer wall by a plurality of first cavities and first ribs;

a second inner wall spaced from the first inner wall by a plurality of second cavities and second ribs; and

a second outer wall extending from the leading edge to the trailing edge integrally formed with the second inner wall, and spaced from the second inner wall by a plurality of third cavities and third ribs;

wherein each of the first and second outer walls, and the first and second inner walls includes a first thickness portion at a first radial position along the radial axis, the first thickness portion being less than 0.018″ (0.457 mm); and

wherein each of the first and second outer walls, and the first and second inner walls includes a second thickness portion at a second radial position along the radial axis, the second thickness portion being between 0.040″ (1.02 mm) and 0.050″ (1.27 mm).

4. The dual wall component of claim 3 , wherein the component is a blade extending radially from a root to a tip, and wherein the first radial position of the first thickness portion is nearer the blade tip than is the second radial position of the second thickness portion.

5. The dual wall component of claim 4 , wherein the second radial position of the second thickness portion is nearer the root than is the first radial position of the first thickness portion.

6. The dual wall component of claim 3 , wherein the first and second outer walls and the first and second inner walls comprise a directionally solidified material.

7. The dual wall component of claim 3 , wherein the first and second outer walls and the first and second inner walls comprise an equiaxed material.

8. The dual wall component of claim 3 , wherein the component is a vane.

9. The dual wall component of claim 3 , wherein the component is a blade outer air seal.

10. A method for forming a dual wall component extending along a radial axis, the method comprising:

forming an outer wall;

forming an inner wall integral to the outer wall, wherein the inner wall and the outer wall are separated by a first cavity; and

forming a third wall, wherein the third wall and the inner wall are separated by a second cavity, and wherein the outer wall, the inner wall and the third wall are formed by additive manufacturing and without using cores to form the first and second cavities;

wherein forming each of the outer wall, the inner wall, and the third wall comprises forming, at a first radial position, a first thickness portion, and forming, at a second radial position, a second thickness portion, the second thickness portion being greater than the first thickness portion.

11. The method of claim 10 , further comprising:

forming a second outer wall, wherein the second outer wall and the third wall are separated by a third cavity, and wherein the second outer wall is formed by additive manufacturing and without using a core to form the third cavity.

12. The method of claim 11 , further comprising:

forming at least one rib between the third wall and the second outer wall.

13. The method of claim 10 , wherein the dual wall component is a blade comprising a root and a tip.

14. The method of claim 13 , wherein the additive manufacturing progresses from root to tip.

15. The method of claim 10 , further comprising:

forming at least one rib between the outer wall and the inner wall.

16. The method of claim 10 , further comprising:

forming at least one rib between the inner wall and the third wall.

17. The method of claim 10 , wherein forming the outer wall, forming the inner wall and forming the third wall are performed using direct metal laser sintering.

18. The method of claim 10 , wherein forming the outer wall, forming the inner wall and forming the third wall are performed using electron beam melting.

19. The method of claim 10 , wherein the additive manufacturing provides an opening that extends through at least one of the outer wall, the inner wall and the third wall.

20. The method of claim 10 , further comprising:

drilling an opening in the outer wall.