Additive manufacturing system and method of manufacture
An additive manufacturing method includes segmenting a CAD file of a component along a build interface to define at least a first component segment and a second component segment, each of the first component segment and the second component segment sized to fit within an additive manufacturing build chamber; additive manufacturing the first component segment and the second component segment within the build chamber; and bonding the first component segment and the second component segment to form the component.
1. A method for manufacturing a hybrid component, comprising:
selecting a build interface in an electronic file for a portion of the hybrid component which is to be additively manufactured in an additive manufacturing build chamber, wherein the portion of the hybrid component comprises a one-piece previously designed additively manufactured part larger than the additive manufacturing build chamber;
electronically segregating the electronic file representative of the portion of the hybrid component along the build interface to define at least a first additively manufactured component segment and a second additively manufactured component segment, each of the first additively manufactured component segment and the second additively manufactured segment are sized to fit simultaneously within the additive manufacturing build chamber;
simultaneously additive manufacturing the first additively manufactured component segment and the second additively manufactured component segment within the additive manufacturing build chamber; and
bonding the first additively manufactured component segment and the second additively manufactured component segment outside of the additive manufacturing build chamber to form the portion of the hybrid component which is to be additively manufactured, and bonding the portion of the hybrid component to a non-additively manufactured part to form the hybrid component wherein the hybrid component is selected from the group comprising trailing edge components that are attached to engine inlet sections, fan stators, compressor stators, turbine exhaust cases and exhaust mixers.
2. The method as recited in claim 1 , further comprising modifying at least one of the first additively manufactured component segment and the second additively manufactured component segment to include a sacrificial material portion to at least one of the first additively manufactured component segment and the second additively manufactured component segment beyond the build interface.
3. The method as recited in claim 2 , further comprising removing the sacrificial material portion during the bonding.
4. The method as recited in claim 1 , further comprising modifying the first additively manufactured component segment and/or the second additively manufactured component segment to add thickness within the first additively manufactured component segment and/or the second additively manufactured component segment along the build interface.
5. The method as recited in claim 1 , wherein selecting the build interface comprises defining the build interface along an internal rib.
6. The method as recited in claim 1 , wherein selecting the build interface comprises defining the build interface at least partially around an aperture.
7. The method as recited in claim 1 , wherein selecting the build interface comprises defining the build interface across the component.
8. The method as recited in claim 1 , wherein selecting the build interface comprises defining the build interface transverse to a longitudinal length of the component.
9. The method as recited in claim 1 , wherein selecting the build interface comprises defining the build interface at least partially around an aperture of the one-piece previously designed additively manufactured part.
10. The method as recited in claim 9 , further comprising defining the build interface across the component.
11. The method as recited in claim 9 , further comprising defining the build interface transverse to a longitudinal length of the component.
12. The method as recited in claim 1 , wherein the bonding of the first additively manufactured component segment and the second additively manufactured component segment includes welding.
13. The method as recited in claim 1 , wherein the additive manufacturing step comprises powder bed additive manufacturing the first additively manufactured component segment and the second additively manufactured component segment within the additive manufacturing build chamber based on the defined first additively manufactured component segment and second additively manufactured component segment.