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Method for fabrication of three-dimensional articles by thermal spray deposition using masks as support structures

  • US 5,203,944 A
  • Filed: 10/10/1991
  • Issued: 04/20/1993
  • Est. Priority Date: 10/10/1991
  • Status: Expired due to Fees
First Claim
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1. A method for the fabrication of a three dimensional article comprising the steps ofa) creating a set of masks, each mask comprised of a support layer and a removable liner thereon, having a cut-away portion through the support layer and liner, each mask corresponding to at least a portion of a cross section through the article such that there is at least one mask for every parallel cross section through the article normal to a centerline through the article;

  • b) placing on a work surface at least one mask;

    c) applying deposition material over the mask to form a layer of deposition material having a first layer portion within the cut-away area and adjacent the support layer of the mask and a second layer portion on the liner;

    d) removing the liner and deposition material thereon after applying the deposition material thereby leaving the support layer and the first layer portion;

    e) placing another mask selected from the set of masks on the support layer;

    f) applying deposition material over the another mask;

    g) removing the liner portion of the another mask and any deposition material thereon;

    h) repeating steps e) through g) until the article has been formed and;

    i) removing the support layers from the article.

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