Seal structure and method of forming

A method, comprising:

• forming a body with an integrally formed protruding portion by additively fusing material, the body having an outer surface and a cavity having a first opening along the outer surface, the outer surface configured to engage a contact member with the first opening of the body facing and aligned with a second opening of the contact member,
• wherein the protruding portion outwardly projects from the outer surface and at least partially surrounds the first opening into the cavity of the body, an inner surface of the protruding portion defining at least a portion of a channel, wherein the protruding portion is configured to engage the contact member and at least partially collapse into the channel while the protruding portion is pressed against the contact member to provide a seal between the body and the contact member that at least partially surrounds the second opening of the contact member and the cavity of the body,
• wherein the body is formed for the first opening of the body to align with the second opening of the contact member so that one or more fluids pass between the contact member and the cavity of the body with the protruding portion inhibiting the one or more fluids from passing between the contact member and the outer surface of the body.

A seal structure, comprising:

• a body having an outer surface and a cavity having a first opening along the outer surface, the outer surface configured to engage a contact member with the first opening of the body facing and aligned with a second opening of the contact member, the first opening having a generally rectangular shape along the outer surface with four edges,
• wherein the body also includes an integrally formed protruding portion that outwardly projects from the outer surface and surrounds the first opening into the cavity along at least three of the four edges, an inner surface of the protruding portion defining at least a portion of a channel, the protruding portion configured to engage the contact member and at least partially collapse into the channel while the protruding portion is pressed against the contact member to provide a seal between the body and the contact member that at least partially surrounds the second opening of the contact member and the cavity of the body,
• wherein the body and the seal are composed of one or more stacks of material layers fused together.