Method and apparatus for fabrication of three-dimensional articles by thermal spray deposition

A method for fabrication of a three-dimensional article comprising the steps of:

• a) creating a first set of masks, each mask corresponding to at least a portion of a cross section through the article such that there is at least one mask in the first set for every parallel cross section through the article normal to a centerline through the article;
• b) placing at least one mask over a work surface;
• c) spraying a deposition material over the work surface and mask placed thereover;
• d) removing the at least one mask;
• e) spraying a complementary material over the work surface and deposition material sprayed thereon to form a layer of deposition material and complementary material;
• f) machining the layer to a selected thickness thereby removing all complementary material from an exposed top surface of the deposition material;
• g) repeating steps b thru f as necessary to build up the article;
• and
• h) removing the complementary material from the deposition material.

An apparatus for forming an integral three-dimensional article by thermally spraying layers of material comprising:

• a) a work surface;
• b) means for supplying to the work surface masks corresponding to cross sections through the article;
• c) means for placing the masks over the work surface and removing them therefrom in accordance with a predetermined sequence;
• d) means for thermally spraying a deposition material over the masks, the work surface, and material deposited on a work surface, and
• e) means for thermally spraying a complementary material over the masks, the work surface and material deposited on the mask surface.