System and method for locating and joining part sections enabled by additive manufacturing

A method for joining part sections, the method comprising:

• splitting a part to have at least two separate sections, including a first section and a second section;
• forming a locating feature as locator structures integral with the first section formed of a first single layer of material that has a first surface and a second surface facing away from the first surface, and with the second section formed of a second single layer of material that has a third surface and a fourth surface facing away from the third surface;
• locating, by the locating feature, the first section relative to the second section with the second surface disposed facing the third surface;
• forming a joining feature as lock structures integral with the first section at the second surface and with the second section at the third surface;
• locking, by the joining feature, the first section relative to the second section, when the first and second sections are located relative to each other by the locating feature;
• containing the joining feature including the lock structures within a thickness of a combination of the first section and the second section between the first surface and the fourth surface with no opening through the first surface and the fourth surface at the joining feature;
• maintaining the first surface and the fourth surface free of features of the joining feature, meaning the joining feature is not visible at the first surface and the fourth surface;
• joining a third section and a fourth section along with the first section and the second section in the part, along two overlapping joints that cross one another at a point, wherein the locating feature is disposed at the point;
• and
• locating, by the location feature, the first section, the second section, the third section and the fourth section, wherein the lock structures are distributed along the two overlapping joints.

A system for joining part sections, the system comprising:

• a part having a design with a complex surface, the design split into at least two separate sections, including a first section formed of a first single layer of material that has a first surface and a second surface facing away from the first surface, and a second section formed of a second single layer of material that has a third surface and a fourth surface facing away from the third surface, the first section and the second section defining a seam along the complex surface;
• a locating feature including a first structure integrally formed with the first section and a second structure integrally formed with the second section, the first structure and the second structure configured to locate the first section relative to the second section with the second surface disposed facing the third surface;
• and
• a joining feature including a third structure integrally formed with the first section at the second surface and a fourth structure integrally formed with the second section at the third surface, the third and fourth structures configured to lock the first section relative to the second section,
• wherein the joining feature including the third and fourth structures is contained within a thickness of a combination of the first section and the second section between the first surface and the fourth surface with no opening through the first surface and the fourth surface at the joining feature so that the first surface and the fourth surface are free of features of the joining feature, meaning the joining feature does not extend through the first surface and the fourth surface,
• wherein the part comprises the first section, the second section, a third section and a fourth section, configured to be joined along two overlapping joints that cross one another at a point, wherein the locating feature is disposed at the point and is configured to locate the first section, the second section, the third section and the fourth section, wherein the lock structures are distributed along the two overlapping joints, wherein the two overlapping joints include a first joint and a second joint wherein the lock structures distributed along the first joint are parallel to each other, the lock structures distributed along the second joint are parallel to each other and are not parallel to the lock structures distributed along the first joint.