Three-dimensional parts having interconnected Hollow patterns, method of manufacturing and method of producing composite part

A method of additive manufacturing a sacrificial tooling part having an interconnected hollow triangular fill pattern, the method comprising:

• printing a outer wall portion having an outer surface and an inner surface;
• printing a first section comprising a plurality of triangular shaped cell layers, wherein the triangle cells are formed by segments, wherein each segment extends in a substantially straight line between two points on the inner surface;
• and
• printing a second section comprising a plurality of hexagram shaped cell layers over the first section of triangular shaped cell layers, wherein the hexagram cells comprise hexagon cells that have common triangle cells,
• wherein the hexagram cells are formed by segments, wherein each segment extends in a substantially straight line between two points on the inner surface wherein when the first and second set of cell sections are printed the triangle cells interconnect with the hexagram cells.

A method of manufacturing a sacrificial tooling part in a layer by layer manner utilizing an additive manufacturing device, the sacrificial tooling part configured for use in making a composite part, the method comprising:

• printing layers of an outer wall portion having an outer surface and an inner surface using an additive manufacturing technique with a water soluble or disintegrable material, wherein the outer wall surface defines a shape of the desired composite part;
• printing a first section comprising a plurality of triangular shaped cell layers using the additive manufacturing technique with a water soluble or disintegrable material, wherein the triangle cells are formed by segments, wherein each segment extends in a substantially straight line between two points on the inner surface;
• and
• printing a second section comprising a plurality of hexagram shaped cell layers over the first section of triangular shaped cell layers using the additive manufacturing technique with a water soluble or disintegrable material, wherein the hexagram cells comprise hexagon cells that have common triangle cells, wherein the hexagram cells are formed by segments, wherein each segment extends in a substantially straight line between two points on the inner surface wherein when the first and second set of cell sections are printed the triangle cells interconnect with the hexagram cells;
• and
• repeating the printing of the first and second cell sections within the outer wall portion until the sacrificial tooling part is built where the next printed sections are rotated an angle relative to the previously printed layers.