TECHNICAL FIELD

The present disclosure generally relates to manufacturing methods, systems, and parts formed therewith and, more particularly, relates to a system and method for forming a part from a rapidly manufactured article.

BACKGROUND

Parts may be manufactured using a variety of methods. Certain characteristics of the part may be affected by the manufacturing method used to make the part. For example, the geometry of the part, the surface roughness, the material characteristics, and/or other features may be dependent on the manufacturing methods that are employed.

Additionally, different manufacturing methods present certain challenges and limitations. Some methods may be more energy efficient than others. Some methods may be more labor intensive than others, may require expensive machinery, etc. These considerations should be taken into account when deciding how to manufacture parts.

There remains a need for improved manufacturing methods that have high efficiency. There also remains a need for methods that can be used to make complex parts accurately and repeatably. Other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.

BRIEF SUMMARY

In one embodiment, a method of manufacturing a part is disclosed. The method includes providing a material that includes a plurality of particles and a binder that is uncured. The method also includes forming a first article from the material including curing the binder to bind a collection of the particles together into the first article. Furthermore, the method includes encasing at least a portion of the first article with an outer member. The outer member defines an internal cavity that corresponds to the first article. Additionally, the method includes heating the outer member and the first article to melt the collection of particles into a molten mass within the internal cavity of the outer member. Moreover, the method includes solidifying the molten mass within the outer member to form a second article. The second article corresponds to at least a portion of the internal cavity of the outer member.

In another aspect, a method of manufacturing a part includes providing a particulated material and forming a first article from the particulated material. The first article defines an exterior and defines a first internal aperture. The method also includes providing a flowing core material within the first internal aperture. Furthermore, the method includes converting the flowing core material to a solid core within the first internal aperture. Still further, the method includes encasing the first article and the solid core with an outer member. The outer member defines an internal cavity surface that corresponds to at least part of the exterior of the first article. Additionally, the method includes heating the outer member, the first article, and the solid core to melt the first article into a molten mass within the internal cavity of the outer member. Moreover, the method includes re-solidifying the molten mass within the outer member and about the solid core to form a second article. An outer surface of the second article corresponds to the internal cavity surface of the outer member. The second article includes a second internal aperture corresponding to the solid core.

