Method of producing patterns, molds, and related products

An additive manufacturing method, comprising:

• forming a plurality of individual layer segments with a porous material;
• placing at least two first layer segments adjacent to each other to form a first layer, wherein the first layer includes at least two seams;
• placing a second layer segment on the at least two first layer segments to form a portion of a second layer, the second layer segment partially overlapping the at least two first layer segments;
• forming holes in the first layer and in the second layer;
• aligning the holes in the first layer with the holes in the second layer such that the second layer overlaps at least one seam of the at least two seams;
• and
• inserting fasteners through the holes in the first layer and the holes of the second layer, wherein at least one fastener is received by the second layer at a position radially inward of the first layer.

An additive manufacturing method, comprising:

• forming a plurality of individual layer segments with a porous material;
• forming a first layer with at least two first layer segments;
• placing at least two second layer segments on the at least two first layer segments to form at least a portion of a second layer, each of the at least two second layer segments of the second layer partially overlapping the at least two first layer segments;
• forming holes in the first layer and in the second layer;
• aligning the holes in the first layer with the holes in the second layer such that the second layer overlaps at least one seam of at least two seams formed with the first layer;
• wherein, after the aligning, at least one hole of the plurality of holes in the second layer is radially offset inwards relative to the first layer;
• and
• applying resin to the first layer and to the second layer, the resin, upon solidifying, permanently bonding the first layer and the second layer.