Additive manufactured part with enhanced rigidity and method of manufacturing the same

Abstract

An additive manufactured part is formed as a solid body of material including additive manufacturing powder, binder material supporting the powder in the shape of the solid body, and strengthening resin infused within the solid body. The additive manufacturing powder can be sand. The infused resin can be a two-part resin wherein an inert gas is added to the mixture of the two parts of the two-part resin during mixing. The infused resin can be infused inwardly from the peripheral surface of the solid body and can penetrate partially or fully through the thickness of the solid body.

1 - 13 . (canceled) 
     
     
         14 . An apparatus comprising:
 a solid body of material having a shape, wherein the material includes additive manufacturing powder, binder material supporting the additive manufacturing powder in the shape of the solid body, and resin infused within the solid body,   wherein the resin is a two-part resin including a resin and a hardener,   wherein an inert gas is applied to the two-part resin during mixture of the resin and the hardener,   wherein the solid body has the configuration of a tool, and   wherein the tool is a vacuum mold tool having a forming surface and air flow channels communicating with the forming surface.   
     
     
         15 . (canceled) 
     
     
         16 . The apparatus of  claim 14 , wherein the solid body has a peripheral surface, and the infused resin penetrates inwardly from the peripheral surface. 
     
     
         17 . The apparatus of  claim 16 , wherein the solid body has a thickness between opposed portions of the peripheral surface, and the infused resin penetrates partially through the thickness. 
     
     
         18 . The apparatus of  claim 16 , wherein the solid body has a thickness between opposed portions of the peripheral surface, and the infused resin penetrates fully through the thickness. 
     
     
         19 - 20 . (canceled) 
     
     
         21 . The apparatus of  claim 14 , wherein the vacuum mold tool has trim lines on the forming surface. 
     
     
         22 . The apparatus of  claim 21 , wherein the trim lines are defined by cuts in the forming surface. 
     
     
         23 . An apparatus comprising:
 a mold tool having a forming surface and air flow channels communicating with the forming surface;   wherein the mold tool includes additive manufacturing powder, a binder supporting the additive manufacturing powder as a solid body having the forming surface, and resin infused within the solid body,
 wherein the resin is a two-part resin including a resin and a hardener, and 
 wherein an inert gas is applied to the two-part resin during mixture of the resin and the hardener. 
   
     
     
         24 . (canceled) 
     
     
         25 . The apparatus of  claim 23 , wherein the solid body has a peripheral surface, and the infused resin penetrates inwardly from the peripheral surface. 
     
     
         26 . The apparatus of  claim 25 , wherein the solid body has a thickness between opposed portions of the peripheral surface, and the infused resin penetrates partially through the thickness. 
     
     
         27 . The apparatus of  claim 25 , wherein the solid body has a thickness between opposed portions of the peripheral surface, and the infused resin penetrates fully through the thickness. 
     
     
         28 . The apparatus of  claim 23 , wherein the mold tool has trim lines on the forming surface. 
     
     
         29 . The apparatus of  claim 28 , wherein the trim lines are defined by cuts in the forming surface. 
     
     
         30 . The apparatus of  claim 23 , further comprising a base having air flow channels configured to communicate with the air flow channels in the mold tool, and rails supporting the mold tool for sliding movement across the base. 
     
     
         31 - 34 . (canceled) 
     
     
         35 . An apparatus comprising:
 a mold tool having a forming surface and air flow channels communicating with the forming surface;   wherein the mold tool includes additive manufacturing powder, a binder supporting the additive manufacturing powder as a solid body having the forming surface, and resin infused within the solid body,   wherein the resin is a two-part resin including a resin and a hardener, and   wherein an inert gas is applied to the two-part resin during mixture of the resin and the hardener; and   wherein the mold tool includes an ejector element extending through the forming surface.   
     
     
         36 . The apparatus of  claim 35 , wherein the ejector element is flush to the forming surface. 
     
     
         37 . The apparatus of  claim 35 , wherein the ejector element includes an air line extending from an underside of the ejector element. 
     
     
         38 . (canceled) 
     
     
         39 . The apparatus of  claim 35 , wherein the ejector element further comprises a poppet. 
     
     
         40 . The apparatus of  claim 39 , wherein the poppet can move between a retracted position and an extended position. 
     
     
         41 . The apparatus of  claim 40 , wherein the ejector element receives a flow of pressurized air, the pressurized air moves the poppet to an extended position, and the pressurized air flows through the ejector element. 
     
     
         42 . The apparatus of  claim 41 , wherein a vacuum formed material is oriented in contact with the forming surface, and wherein the poppet applies force to the vacuum formed material when the poppet is in the extended position.