High strength part

Abstract

High-strength parts are produced by first performing a stereolithography part generation process to create a polymer part having opposing interior surfaces. An uncured strength material is interposed between the opposing interior surfaces of the polymer part. The polymer part with the uncured strength material is then heated. The strength material is chosen to bond to the opposing interior surfaces during the heating step.

What is claimed is:  
     
         1 . A method for producing high-strength parts, comprising the steps of: 
 performing a stereolithography part generation process to create a polymer part having opposing interior surfaces;    interposing an uncured strength material between said opposing interior surfaces; and    heating said polymer part with said uncured strength material interposed between said opposing interior surfaces, wherein said uncured strength material cures and bonds to said opposing interior surfaces.    
     
     
         2 . A method according to  claim 1  wherein said step of performing includes the step of generating a plurality of spaced apart internal supports integral with and between said opposing interior surfaces during said stereolithography part generation process to a gap between said opposing interior surfaces.  
     
     
         3 . A method according to  claim 2  wherein: 
 said step of performing further includes the step of providing a first hole and a second hole in said polymer part, each of said first hole and said second hole communicating with said gap; and  
 said step of filling includes the step of injecting said uncured strength material into said first hole.  
 
     
     
         4 . A method according to  claim 3  further comprising the step of applying a vacuum to said second hole while said uncured strength material is injected into said first hole.  
     
     
         5 . A method according to  claim 1  wherein: 
 said step of performing creates a first shell of said polymer part and creates a second shell of said polymer part that can be nested with said first shell to define said opposing interior surfaces; and  
 said step of filling is accomplished by sandwiching said first shell and said second shell about said uncured strength material.  
 
     
     
         6 . A method according to  claim 5  wherein said step of filling comprises the steps of: 
 placing a mesh between said first shell and said second shell;  
 wetting said mesh with a catalyzed resin to form said uncured strength material; and  
 pressing said first shell and said second shell together about said mesh wetted with said catalyzed resin, wherein said mesh conforms to said opposing interior surfaces.  
 
     
     
         7 . A high-strength part, comprising: 
 a part made from a photo-curable polymer, said part having opposing interior surfaces; and    a strength material interposed between and bonded to said opposing interior surfaces.    
     
     
         8 . A high-strength part as in  claim 7  further comprising a plurality of spaced apart internal supports made from said photo-curable polymer, said plurality of spaced apart internal supports further being integral with said opposing interior surfaces to create a gap therebetween.  
     
     
         9 . A high-strength part as in  claim 7  wherein said strength material comprises a mixture of an epichlorohydrin resin, a catalyst and filler particles.  
     
     
         10 . A high-strength part as in  claim 9  wherein said catalyst is selected from the group consisting of methylendomethylene, hexahydrophthalic anhydride, dodecenylsuccinic anhydride, and polyamide.  
     
     
         11 . A high-strength part as in  claim 9  wherein said catalyst is methylendomethylene mixed with said epichlorohydrin resin in a proportion of 80-90 weight percent of said epichlorohydrin resin.  
     
     
         12 . A high-strength part as in  claim 11  wherein said filler particles are glass fibers in the range of {fraction (1/32)} to {fraction (1/64)} of an inch in length.  
     
     
         13 . A high-strength part as in  claim 12  wherein said glass fibers are 50-60 weight percent of said epichlorohydrin resin.  
     
     
         14 . A high-strength part as in  claim 9 , said mixture further comprising aluminum powder in a proportion up to 10 weight percent of said epichlorohydrin resin.  
     
     
         15 . A high-strength part as in  claim 7  wherein said strength material comprises a mesh wetted with a catalyzed epichlorohydrin resin.  
     
     
         16 . A high-strength part as in  claim 15  wherein said catalyzed epichlorohydrin resin uses a catalyst selected from the group consisting of methylendomethylene, hexahydrophthalic anhydride, dodecenylsuccinic anhydride, and polyamide.  
     
     
         17 . A high-strength part as in  claim 16  wherein said catalyst is methylendomethylene mixed with a epichlorohydrin resin in a proportion of 80-90 weight percent of said epichlorohydrin resin.