Additive manufacturing system and method of manufacture

An additive manufacturing method for additive manufacturing an aerospace component in an additive manufacturing build chamber, the method comprising:

• selecting a build interface in an electronic file for the component, wherein the component comprises a one-piece previously designed additively manufactured part larger than the additive manufacturing build chamber, the build interface selected to avoid operational impact to the component;
• electronically segregating the electronic file representative of the 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 component segment are sized to fit simultaneously within the additive manufacturing build chamber, the first additively manufactured component segment different than the second additively manufactured component segment;
• simultaneously 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;
• 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 component, wherein the aerospace component is a component of a gas turbine engine, wherein the component of the gas turbine engine 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.