Multidimensional hybrid lap joints and additive manufacturing processes for making bezel assemblies

A light fixture bezel assembly, comprising:

• a first U-shaped part integrally formed as a first single-piece structure with a first curvilinear part body and a pair of rectilinear first legs projecting from opposing ends of the first part body, each of the first legs including a first terminal end with a first lap joint (LJ) section, the first LJ section including multiple adjoining and mutually non-coplanar first LJ walls and multiple snap-lock (SL) protrusions projecting outward from the first LJ walls;
• and
• a second U-shaped part integrally formed as a second single-piece structure with a second curvilinear part body and a pair of rectilinear second legs projecting from opposing ends of the second part body, each of the second legs including a second terminal end with a second LJ section, the second LJ section including multiple adjoining and mutually non-coplanar second LJ walls and multiple pairs of SL teeth projecting inward from the second LJ walls,
• wherein the second LJ walls of each of the second LJ sections collectively define a lap joint channel slidably receiving therein and interference fitting with the first LJ walls of a respective one of the first LJ sections, and
• wherein each of the pairs of SL teeth receives therebetween and snap fits with a respective one of the SL protrusions to thereby lock the first part to the second part.

A method of manufacturing a multipart assembly, the method comprising:

• printing, using an additive manufacturing (AM) process, a first part including a first part body with a first leg projecting from the first part body, the first leg including a first terminal end with a first lap joint (LJ) section, the first LJ section including multiple mutually non-coplanar first LJ walls and multiple snap-lock (SL) protrusions projecting outward from the first LJ walls;
• printing, using the AM process, a second part including a second part body with a second leg projecting from the second part body, the second leg including a second terminal end with a second LJ section, the second LJ section including multiple mutually non-coplanar second LJ walls and multiple pairs of SL teeth projecting inward from the second LJ walls, the second LJ walls collectively defining a lap joint channel;
• sliding the first LJ walls into the lap joint channel defined by the second LJ walls to thereby interference fit the first LJ section with the second LJ section;
• and
• pressing a respective one of the SL protrusions into each of the pairs of SL teeth to thereby snap fit the first LJ section with the second LJ section and join the first and second parts.