CPC B29C 43/10 (2013.01) [B29C 39/10 (2013.01); B29C 43/12 (2013.01); B29C 64/30 (2017.08); B29C 64/386 (2017.08); B29C 71/02 (2013.01); B33Y 40/00 (2014.12); B33Y 40/20 (2020.01); B33Y 50/00 (2014.12); B29C 2043/3261 (2013.01); B29C 2043/562 (2013.01); B29K 2307/04 (2013.01)] | 21 Claims |
1. A method for consolidating an additively manufactured piece, the method comprising:
placing an assembly in a cavity of a thermally conductive container, the assembly comprising a first piece and a second piece with one or more of the first and the second pieces being additively manufactured;
filling the cavity with one of a liquid and a semi-liquid curable material which directly contacts and completely surrounds the assembly, the curable material having a maximum operating temperature higher than a lower melt temperature of at least one of the first and the second pieces of the assembly, and having a positive thermal coefficient of expansion relative to the container,
sealing the cavity;
curing the curable material so that the cured material restricts movement of the assembly in the cavity;
heating the container to increase the temperature within the container to cause the cured material to expand and create a pressure on the assembly, wherein the temperature is increased by the heating until the temperature reaches a process temperature equal or higher than the lower melt temperature of at least one of the first and the second pieces of the assembly and lower than the maximum operating temperature of the cured material; and
maintaining the process temperature within the container for a time interval to consolidate the assembly;
wherein during the heating of the container and maintaining the process temperature for the time interval, the cured material forms an in-situ monobloc mold for the assembly.
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