APPARATUS AND PROCESS FOR SEALING OF GAPS IN PARTS MANUFACTURED VIA 3D PRINTING TECHNIQUES

1 . A method of sealing gaps in a component, comprising:

generating vapor from a liquid;

directing the vapor to an exposed surface of a component, wherein the component includes a plurality of layers of an extrudate and gaps between the plurality of layers and wherein the extrudate includes an outer portion;

softening the outer portion of the extrudate at the exposed surface; and

filling the gaps with the softened outer portion of the extrudate.

2 . The method of claim 1 , wherein the exposed surface is a channel defined within the component.

3 . The method of claim 2 , wherein the component is a tool and the channel is a cooling line.

4 . The method of claim 1 , wherein the extrudate has a glass transition temperature and the method further comprises adjusting at least one of a vapor temperature and vapor pressure to raise the outer portion of the extrudate to a temperature greater than the glass transition temperature of the extrudate.

5 . The method of claim 4 , wherein the extrudate includes an outer surface and the outer portion is up to 10% of a thickness of the extrudate from the outer surface.

6 . The method of claim 5 , wherein the outer portion of the extrudate includes a sheath having a lower glass transition temperature than a glass transition temperature of a core of the extrudate surrounded by the sheath.

7 . The method of claim 1 , wherein directing the vapor comprises inducing a laminate flow.

8 . The method of claim 1 , wherein directing the vapor comprises inducing a swirling or turbulent flow.

9 . The method of claim 8 , wherein the liquid is a weak acid.

10 . The method of claim 8 , wherein the liquid is an organic alcohol.

11 . The method of claim 1 , wherein the liquid is water.

12 . An apparatus for sealing gaps in a 3D component, comprising:

a heating chamber including at least one first heating element;

a vapor chamber coupled to the heating chamber;

a pressure regulator operatively coupled to the vapor chamber; and

a nozzle coupled to the vapor chamber by a duct.

13 . The apparatus of claim 12 , further comprising at least one thermocouple operatively coupled to the heating chamber.

14 . The apparatus of claim 12 , wherein the vapor chamber includes at least one second heating element.

15 . The apparatus of claim 12 , further comprising at least one second thermocouple associated with the vapor chamber.

16 . The apparatus of claim 12 , wherein the at least one first heating element is located within the heating chamber.

17 . The apparatus of claim 12 , further comprising a bladder located in the vapor chamber.

18 . The apparatus of claim 12 , further comprising a plurality of nozzles.

19 . A tool, comprising:

a component including an extrudate arranged in layers, wherein the component includes exposed surfaces;

a cavity defined by a first exposed surface;

a cooling line defined by a second exposed surface; and

a plurality of gaps between the layers, wherein the gaps between the layers at the second exposed surface are sealed with a portion of the extrudate.

20 . A method of making a tool, comprising:

connecting a component to one or more support plates, the component including

an extrudate arranged in layers, wherein the component includes exposed surfaces,

a cavity defined by a first exposed surface,

a cooling line defined by a second exposed surface, and

a plurality of gaps between the layers, wherein the gaps between the layers at the second exposed surface are sealed with a portion of the extrudate.