Method for fabrication of three-dimensional articles by thermal spray deposition using masks as support structures

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

• a) creating a set of masks, each mask comprised of a support layer and a removable liner thereon, having a cut-away portion through the support layer and liner, each mask corresponding to at least a portion of a cross section through the article such that there is at least one mask for every parallel cross section through the article normal to a centerline through the article;
• b) placing on a work surface at least one mask;
• c) applying deposition material over the mask to form a layer of deposition material having a first layer portion within the cut-away area and adjacent the support layer of the mask and a second layer portion on the liner;
• d) removing the liner and deposition material thereon after applying the deposition material thereby leaving the support layer and the first layer portion;
• e) placing another mask selected from the set of masks on the support layer;
• f) applying deposition material over the another mask;
• g) removing the liner portion of the another mask and any deposition material thereon;
• h) repeating steps e) through g) until the article has been formed and;
• i) removing the support layers from the article.