Protective mask by dual material additive manufacturing and related methods

Abstract

The invention is entitled Protective Mask by Dual Material Additive Manufacturing and Related Methods. The invention provides a protective mask (100) for a part (102) that includes a plurality of openings (104) in a surface (106) thereof. The protective mask (100) includes a mounting member (120) that is at least partially within each of at least two of the plurality of openings (104). Each mounting member (120) includes a water-soluble material (160). A masking member (130) couples the at least two mounting members (120). The masking member (130) includes a non-water-soluble material (162). Each mounting member (120) includes a first plurality of integral layers of the water-soluble material (160), and the masking member (130) includes a second plurality of integral layers of the non-water-soluble material (162). The protective mask (100) can be made by a dual material additive manufacturing system (150). The invention also provides a related method.

Description

Background Art

[0001] The present disclosure relates generally to part manufacturing, and more particularly to a protective mask for covering an opening in a surface of a part. The protective mask comprises two components, one of which is made of a water-soluble material. Both components are formed by additive manufacturing.

[0002] Industrial parts may be exposed to a variety of processes after manufacturing to complete the part. In one example, a part may be exposed to shot peening, in which the surface of the part is bombarded with a peening material, such as metal shot. In another example, a part may be coated with a protective layer to protect the underlying material from the harsh environment in which the part will be used. For example, a thermal barrier coating (TBC) may be applied to the outer surface of a turbine rotor blade to protect the blade from high temperatures during use.

[0003] Some parts may include openings in their surfaces that need to be protected during post-molding processing. For example, turbine rotor blades may include various internal cooling circuits that lead to the exterior surface of the part through cooling channels (i.e., openings in the part surface). Cooling channels may be provided to cool the internal structure in which they reside and / or to create a cooling film across the entire exterior surface of the part.

[0004] Various mechanisms are used to protect openings. In some cases, removable materials, such as plugs, may be placed in or over the openings to, for example, prevent them from filling when a coating is applied over them. Removable materials block the coating from entering the openings, but this increases manufacturing time and complexity because the removable material and / or the coating over it must ultimately be removed. For example, the barrier material must be removed for each opening, which can be time-consuming. Furthermore, the coating is typically applied over the barrier material but needs to be removed from it to expose the barrier material and / or the opening. Because the coating bridges over the barrier material, its removal can result in extensive cracking of the remaining portion of the coating (e.g., the TBC), which can render the part unusable or require extensive additional processing. Removing the barrier material after the hammering process can be particularly challenging if the barrier material becomes lodged in the part's material during the process. Other approaches employ shielding features, such as overhangs, to protect the openings. In some cases, the overhangs are removed, in which case they present similar challenges as removable barrier materials. In other cases, the overhangs remain an integral part of the part. In the latter case, the complexity of the part increases, and part performance may be compromised to accommodate the overhangs. Regardless of the approach, current processes for protecting openings in the surface of a part can be challenging because forming and / or removing the protective mask alone can be complex.

[0005] Additive manufacturing (AM) encompasses a variety of processes that produce parts by sequentially layering material rather than removing it. Consequently, AM can form complex geometries without the use of tools, molds, or fixtures of any kind, and with little or no material waste. Rather than machining a part from a solid block of material (much of which is chipped away and discarded), the only material used in AM is that required to form the part. Consequently, many industrial parts, such as turbine rotor blades, are made using AM. Advances in AM have resulted in systems that can print using two different materials. Summary of the Invention

[0006] A first aspect of the present disclosure provides a protective mask for a part comprising a plurality of openings in a surface thereof, the protective mask comprising: a mounting member at least partially positioned within each of at least two of the plurality of openings, wherein each mounting member comprises a water-soluble material; and a masking member coupled to the mounting member, the masking member comprising a non-water-soluble material, and wherein each mounting member comprises a first plurality of integral layers of the water-soluble material and the masking member comprises a second plurality of integral layers of the non-water-soluble material.

[0007] A second aspect of the present disclosure provides an additive manufacturing (AM) structure comprising: a part comprising a plurality of openings in a surface thereof; and a protective mask comprising: a mounting member at least partially located within each of at least two of the plurality of openings, wherein each mounting member comprises a water-soluble material; and a masking member connecting at least two mounting members, the masking member comprising a non-water-soluble material, wherein each mounting member comprises a first plurality of integral layers of the water-soluble material and the masking member comprises a second plurality of integral layers of the non-water-soluble material, and wherein each mounting member and the masking member are formed using at least a dual-material additive manufacturing system.

[0008] A third aspect of the present disclosure provides a method comprising: first sequentially dispensing a fluid water-soluble material layer by layer in a predetermined path to selectively generate a mounting member at least partially located within at least two of a plurality of openings in a surface of a part; and second sequentially dispensing a fluid non-water-soluble material layer by layer in a predetermined path to selectively generate a masking member connecting at least two mounting members.

[0009] The exemplary aspects of the present disclosure are designed to solve the problems described herein and / or other problems not discussed. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] These and other features of the present disclosure will be more readily understood from the following detailed description of various aspects of the disclosure taken in conjunction with the accompanying drawings which depict various embodiments of the disclosure, in which:

[0011] Figure 1 A perspective view of an additive manufacturing (AM) structure including a protective mask on a part is shown in accordance with an embodiment of the present disclosure;

[0012] Figure 2 An enlarged side view of the AM structure including the protective mask on the part is shown in accordance with an embodiment of the present disclosure;

[0013] Figure 3 An enlarged side view of the AM structure including the protective mask on the part is shown in accordance with other embodiments of the present disclosure;

[0014] Figure 4 A side view of sequentially forming a mounting member of a protective mask is shown in accordance with an embodiment of the present disclosure;

[0015] Figure 5 A side view of sequentially forming a masking member of a protective mask is shown in accordance with an embodiment of the present disclosure;

[0016] Figure 6 An enlarged side view of applying a coating to the AM structure is shown in accordance with an embodiment of the present disclosure;

[0017] Figure 7 An enlarged side view of shot peening the AM structure is shown in accordance with an embodiment of the present disclosure; and

[0018] Figure 8 An enlarged side view of dissolving the mounting member is shown in accordance with an embodiment of the present disclosure.

[0019] It should be noted that the figures of the present disclosure are not necessarily drawn to scale. The figures are intended to depict only typical aspects of the present disclosure, and therefore should not be considered as limiting the scope of the present disclosure. In the drawings, like numbering represents similar elements between the figures. DETAILED DESCRIPTION

[0020] As an initial matter, in order to clearly describe the present technology, when referring to and describing related components, it will be necessary to select certain terminology. To the extent possible, generic industry terminology will be used and employed in a manner consistent with accepted meanings of the terminology. Unless otherwise stated, such terminology should be given a broad reading consistent with the context of the present application and the scope of the appended claims. One of ordinary skill in the art will appreciate that a number of different or overlapping terms can be used to reference a particular component. An object that can be described herein as a single part can include multiple components and be referenced elsewhere as being made up of multiple components. Alternatively, an object that can be described herein as including multiple components can be referred to elsewhere as a single part. A number of descriptive terms can be used regularly herein, as outlined below. The terms "first," "second," and "third" can be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components.

[0021] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms "a," "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. "Optional" or "optionally" mean that the subsequently described event or circumstance can or can not occur, and that the description includes instances where the event occurs and instances where it does not.

[0022] In the case of elements or layers referred to as "on," "engaged to," "connected to," or "coupled to" another element or layer, it can be directly on, engaged, connected, or coupled to the other element or layer, or one or more intervening elements or layers can be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0023] As described above, the present disclosure provides a protective mask for a part comprising a plurality of openings in a surface thereof. The protective mask includes a mounting member that is at least partially positioned within each of at least two of the plurality of openings. Each mounting member comprises a water-soluble material. A masking member couples the at least two mounting members. The masking members comprise a water-insoluble material. Each mounting member comprises a first plurality of integral layers of a water-soluble material, and the masking member comprises a second plurality of integral layers of a water-insoluble material. The protective mask can be manufactured using a dual-material additive manufacturing system. The present disclosure also provides a related method.

[0024] Additive manufacturing (AM) includes a variety of processes that produce parts by continuously layering materials rather than removing them. Therefore, additive manufacturing can form complex geometries without the use of any kind of tools, molds or fixtures, and with little or no material waste. Instead of machining parts from a solid material blank (much of which is cut away and discarded), the only material used in additive manufacturing is the material required to form the part. Additive manufacturing technology typically involves taking a three-dimensional computer-aided design (CAD) file of the part to be formed, electronically slicing the part into layers (e.g., 18 to 102 microns thick) and creating a file with a two-dimensional image (including vectors, images or coordinates) of each layer. The file can then be loaded into a preparation software system that interprets the file so that the part can be built by different types of additive manufacturing systems. In the 3D printing, rapid prototyping (RP) and direct digital manufacturing (DDM) forms of additive manufacturing, the material layers are selectively distributed, such as sintered, formed, deposited, etc. to form the part.

[0025] According to embodiments of the present disclosure, 3D printing and more specifically the development of multi-head extruder additive manufacturing technology has advantages in forming protective masks. Among other things, this technology can be referred to as fused deposition modeling (FDM). In these additive manufacturing processes, objects are built by selectively distributing a fluid layer by layer in a predetermined path. The part and / or the dispensing head can move in the XY direction. The part and / or the dispensing head can also move in the vertical direction to accommodate the build. The material used can be, for example, a thermoplastic polymer, ceramic, etc. in fluid form. Once each layer is produced, each two-dimensional slice of the part geometry hardens. The material can harden naturally or can be cured using, for example, cooling, heating, or ultraviolet exposure.

[0026] The part to be protected can be formed by conventional subtractive techniques, but can also be constructed using additive manufacturing. For example, in metal powder additive manufacturing techniques such as direct metal laser melting (DMLM) (also known as selective laser melting (SLM)), layers of metal powder are sequentially melted together to form the part. More specifically, layers of fine metal powder are sequentially melted after being evenly distributed on a bed of metal powder using an applicator. Each applicator includes an applicator element in the form of a die lip, brush, scraper or roller made of metal, plastic, material, carbon fiber or rubber, which spreads the metal powder evenly over the build platform. The metal powder bed can move in a vertical axis. The process occurs in a processing chamber with a precisely controlled atmosphere. Once each layer is formed, each two-dimensional slice of the component geometry can be fused by selectively melting the metal powder. The melting can be performed by a high-power melting beam (such as a 100-watt ytterbium laser) to completely weld (melt) the metal powder to form solid metal. The melting beam is moved in the XY direction using scanning mirrors and is strong enough to completely weld (melt) the metal powder to form solid metal. The metal powder bed can be lowered for each subsequent two-dimensional layer and the process is repeated until the part is fully formed.

[0027] See attached figure, Figure 1 shows a perspective view of a protective mask 100 according to various embodiments of the present disclosure, and Figure 2 An enlarged partial side view of the protective mask is shown. As described above, the protective mask 100 protects the part 102 during post-molding processing of the part (e.g., heat treating, coating, surface finishing, etc.). The part 102 includes a plurality of openings 104 in a surface 106 thereof. The part 102 may include any industrial part now known or later developed. In one non-limiting example, the part 102 may include a turbine rotor blade including various internal cooling circuits (see, e.g., FIG. 1 ) that lead to an exterior surface (e.g., surface 106) of the part through cooling channels. Figure 3 ). Cooling channels may be provided to cool the internal structure in which they are located and / or to form a cooling film on the surface 106 of the part 102. Although not required in all cases, as Figure 1In the example shown, the opening 104 can be positioned in a base 110 in a surface 106 of the part that extends from another surface 112 of the part. The opening 104 can have any cross-sectional shape at the surface 106, such as a circle, an ellipse, a polygon (square, rectangular, trapezoidal, etc.), a diffuser shape, etc., and can extend into the part 102 in any direction relative to the surface 106. The openings 104 can be positioned across the surface 106 in a spaced manner (e.g., equidistant or unequally spaced). The part 102 can be formed using any now known or later developed technology. In one non-limiting example, the part 102 can be formed by additive manufacturing (e.g., DMLM or SLM). Because these processes are well known, the details of the process will not be described in detail except to state that the process includes providing a metal powder bed in a processing chamber and sequentially melting metal powder layers on the metal powder bed to generate the part 102 including the opening 104.

[0028] Continue to refer Figure 1 and Figure 2 , the protective mask 100 may include a mounting member 120 at least partially positioned within each of at least two of the plurality of openings 104. The mounting member 120 may extend into the corresponding opening 104 to any extent necessary to maintain its position in each opening 104 during use. The mounting member 120 may be applied in as few as two openings 104. Figure 2 In FIG. 1 , two mounting members 120 are shown in the opening 104 and in FIG. Figure 1 , twelve mounting members 120 are used in the openings 120. In certain embodiments, each opening 104 may include a mounting member 120 at least partially located therein, such that the mounting members 120 are positioned in a spaced manner across the surface 106 with the openings 104 so arranged. Figure 2 As shown, the mounting members 120 may optionally extend outwardly from the corresponding openings 104 along the surface 106 of the part 102. Figure 2 As shown, mounting member 120 may cover portion 122 of surface 106. Mounting member 120 may have any desired height from surface 106. For example, the height of mounting member 120 may be greater than the height of coating 170 ( Figure 6 ) to prevent bridging of the coating 170 onto the mounting member 120 and / or the masking member 130 (described herein) and to reduce or eliminate cracking of the coating 170 that may result during removal of the protective mask 100.

[0029] According to an embodiment of the present disclosure, each mounting member 120 comprises a water-soluble material, i.e., it is capable of being dissolved by water. The water-soluble material may include any now known or later developed water-soluble polymer, ceramic, etc. (which can withstand the environment of the process applied in place with the protective mask 100). In a non-limiting example, the water-soluble material may include a water-soluble ceramic that can withstand heat treatment, coating treatment (such as application of TBC), and shot peening of the surface 106, etc.

[0030] Protective mask 100 may also include a masking member 130 that connects at least two mounting members 120. In contrast to mounting members 120, masking member 130 comprises a water-insoluble material, meaning it cannot dissolve in water. The water-insoluble material may include any now known or later developed water-insoluble material, such as, but not limited to, polymers or ceramics, which, once hardened, can withstand the processing environments associated with protective mask 100. Furthermore, the water-insoluble material should also possess sufficient structural strength to maintain its position and that of mounting members 120.

[0031] The masking member 130 can take any form of structure capable of coupling the mounting members 120 together and at least partially covering the mounting members 120. In one non-limiting example, the masking member 130 can include a first member 132 coupled to a respective one of the at least two mounting members 120 and a second member 134 coupling each of the first members 132 together. The first member 132 can include any structure capable of coupling together the different materials of the first member 132 and the mounting members 120. The first member 132 can also include any structure that allows for easy removal (e.g., "breaking") of the protective mask 100, such as by prying points and / or gripping locations. Although in Figure 2 is shown as having surface-to-surface contact, but as Figure 3 As shown, the first member 132 and / or the mounting member 120 may have an interaction structure 136 that couples them together, such as, but not limited to, a male-female interface, adhesive material, etc. The masking member 130, more specifically the first member 132 thereof, covers at least a portion of each mounting member 120. Figure 1 and Figure 2 In FIG. 1 , the masking member 130 covers most, if not all, of the mounting member 120. However, as Figure 3 As shown, the masking member 130 may expose a portion 138 of the mounting member 120. The latter arrangement may be desirable, for example, where the material of the mounting member 120 is less expensive than the material of the masking member 130 and the material of the mounting member 120 can withstand the processing environment without damage (even though it is exposed).

[0032] Figures 1 to 3Also shown is an additively manufactured (AM) structure 140 including the part 102 and the protective mask 100 .

[0033] like Figure 4 and Figure 5 As shown, a method according to an embodiment of the present invention may include forming at least two mounting members 120 and a masking member 130 using at least a dual-material additive manufacturing (AM) system 150. The AM system 150 may include any now known or later developed additive manufacturing system capable of printing with two materials (e.g., a water-soluble material for the mounting member 120 and a non-water-soluble material for the masking member 130). In one non-limiting example, the AM system 150 may be based on FDM technology, as described herein. As shown, the AM system 150 may include a dual dispensing head 152; however, a single dispensing head capable of processing two materials is also possible. As shown Figure 4 As shown in a cross-sectional view of FIG, the method may include first sequentially dispensing a fluid water-soluble material 160 layer by layer in a predetermined path to selectively generate a mounting member 120 (shown as partially generated) that is at least partially located within at least two of the plurality of openings 104 in the surface 106 of the part 102. As used herein, "dispensing" includes any manner in which the AM system 150 generates layers, such as, but not limited to, laying down, spraying with back pressure, deposition, sintering, etc. Additionally, "fluid" indicates that the material generally does not have a fixed shape and readily yields to external pressure, such as a liquid or paste.

[0034] Figure 5 A second sequential dispensing of a fluid, water-insoluble material 162 is shown, layer by layer, in a predetermined path to selectively generate a masking member 130 (shown as partially generated) that connects at least two mounting members 120. As will be appreciated, the AM system 150 and / or at least a portion of the part 102 can move horizontally as dispensing occurs to generate the layers. It should also be appreciated that the AM system 150 and / or the part 102 can move vertically between layers to accommodate the growth of the AM structure 140. The mounting members 120 can be fully completed before the masking member 130 is initiated, or, if the AM system 150 is capable, both members 120, 130 can be formed simultaneously, e.g., with material changes occurring within a given layer. Because the mounting members 120 and the masking members 130 are additively manufactured, each mounting member 120 comprises multiple integral layers of a water-soluble material, and the masking member 130 comprises multiple integral layers of a water-insoluble material.

[0035] As described herein, the part 102 may be formed by additive manufacturing prior to the first sequential dispensing. For example, the part 102 may be made by another AM system (such as a DMLM machine) that provides a metal powder bed within a process chamber and sequentially fuses layers of metal powder on the metal powder bed to generate the part 102 including the opening 104.

[0036] Figure 6 and Figure 7 Illustrative processes are shown that may be applied to a part 102 having a protective mask 100 applied thereto. It should be emphasized that the illustrative processes are only two of a large number of processes that may be applied to a part 102 having a protective mask 100 thereon. Figure 6 1. The coating 170 is shown applied to the part 102, for example, by thermal spraying or other suitable technique. As shown, the mounting member 120 prevents the coating 170 from entering the opening 104. As previously discussed, the height of the mounting member 120 from the surface 106 can be selected to be greater than the coating 170 to be applied to the part 102 ( Figure 6 ) of the desired thickness. In this manner, mounting member 120 can reduce or prevent bridging of coating 170 onto mounting member 120 and / or masking member 130, and reduce or eliminate cracking of coating 170 that may result during removal of protective mask 100. Coating 170 can include any now known or later developed coating, such as, but not limited to, paint, thermal barrier coating, environmental coating, and the like. Figure 7 Shot peening is shown being applied to the part 102. As shown, the mounting member 120 prevents the peening material 172 (e.g., metal shot) from entering or damaging the opening 104. The masking member 130 covers at least a portion of the mounting member 120 to protect the mounting member 120 during shot peening, for example, if the mounting member is made of a material that cannot withstand shot peening. It should be understood that Figure 7 Shot peening can be Figure 6 Applied before coating.

[0037] Figure 8 The mounting member 120 ( Figures 6 and 7 ) is exposed to water 180 to remove the mounting member 120 and release the masking member 130. The mounting member 120 can be exposed to water 180 in any manner, for example, by delivering a fluid to the mounting member 120, dipping, spraying, etc. In any case, exposure to water 180 dissolves the water-soluble material of the mounting member 120 - only a portion of the member remaining, such as Figure 8 As shown. Once the mounting member 120 is at least largely removed, the shielding member 130 is released, i.e., the shielding member will fall off or can be easily removed. Where possible, the shielding member 130 can be disposed of or reused. Figure 8As shown, the openings 104 are free of any damage or material that can obstruct their intended operation.

[0038] Embodiments of the present disclosure provide a dual material protective mask 100 including an integral printed mounting member 120 that can be "washed away" to allow the remaining portion of the masking member 130 to easily fall off. The protective mask 100 can be easily removed with the aid of gravity and / or pry points and grip locations provided by the first member 132 of the masking member 130. As described above, the integrally attached protective mask 100 can be used for the handling of the part 102. Notably, the protective mask 100 eliminates the expensive machining and / or cleaning of the openings 104 and reduces the risk of damaging the opening geometry, for example, during shot peening. The protective mask 100 can also significantly reduce labor costs as well as plant and equipment costs relative to the electrochemical machining (ECM), laser drilling or ablation that would otherwise be required to clean and / or repair the openings 104. The mounting member 120 can be configured to prevent any coating from bridging over the protective mask, thereby reducing or preventing cracking of the remaining portion of the coating (e.g., TBC) that can render the part unusable or require extensive additional handling.

[0039] As used throughout the specification and claims, approximate language can be used to modify any quantitative representation that can allow for variation without resulting in a change in the basic function to which it is related. Accordingly, a value modified by one or more terms such as "about," "approximately," and "substantially" is not limited to the precise value specified. In at least some instances, the approximate language can correspond to the precision of an instrument used to measure the value. Ranges can be combined and / or interchanged. These ranges are identified and include all subranges therein unless context or language indicates otherwise. "About" applied to numerical values means + / - 10% of the value unless otherwise indicated. The disclosure of the specification and claims is intended to be construed broadly and without limitation to the specific examples and figures set forth herein.

[0040] All devices or steps of corresponding structures, materials, acts, and equivalents of all embodiments or aspects of the claims below are intended to include any structure, material, or act for performing the functions in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or to limit the present disclosure to the precise form disclosed. Many modifications and variations will be apparent to practitioners skilled in the art. Embodiments were chosen and described in order to best explain the principles of the present disclosure and its practical application and to thereby enable others skilled in the art to best utilize the present disclosure in various embodiments and with various modifications as are suited to the particular use contemplated.

Claims

1. A protective mask (100) for a part (102), the part (102) comprising a plurality of openings (104) in a surface (106) thereof, the protective mask (100) comprising: a mounting member (120) positioned at least partially within each of at least two of the plurality of openings (104), wherein each mounting member (120) comprises a water-soluble material (160); and A masking member (130) is coupled to at least two mounting members (120), the masking member (130) comprising a water-insoluble material (162), and wherein each mounting member (120) comprises a first plurality of integral layers of said water-soluble material (160), and said masking member (130) comprises a second plurality of integral layers of said water-insoluble material (162), The masking member (130) includes a first member (132) coupled to a corresponding one of the at least two mounting members (120) and a second member (134) coupling each of the first members (132) together.

2. The protective mask (100) of claim 1, wherein the plurality of openings (104) are positioned in a spaced-apart manner across the surface (106), and wherein each opening (104) includes a mounting member (120) at least partially positioned therein.

3. The protective mask (100) of claim 1, wherein the mounting members (120) extend outwardly from respective openings (104) along the surface (106) of the part (102).

4. The protective mask (100) of claim 1, wherein the at least two mounting members (120) and the masking member (130) are formed using at least a dual-material additive manufacturing system (150).

5. The protective mask (100) of claim 1, wherein the plurality of openings (104) are positioned in a base (110) extending from the surface (106) of the part (102) to another surface (112) of the part (102).

6. The protective mask (100) of claim 1, wherein the masking member (130) covers at least a portion (122, 138) of each mounting member (120).

7. An additively manufactured structure (140), comprising: a part (102) comprising a plurality of openings (104) in a surface (106) thereof; A protective mask (100), comprising: a mounting member (120) positioned at least partially within each of at least two of the plurality of openings (104), wherein each mounting member (120) comprises a water-soluble material (160); and a shielding member (130) coupled to at least two mounting members (120), the shielding member (130) comprising a water-insoluble material (162), wherein each mounting member (120) comprises a first plurality of integral layers of said water-soluble material (160), and said masking member (130) comprises a second plurality of integral layers of said water-insoluble material (162), and wherein each mounting member (120) and the masking member (130) are formed using at least a dual-material additive manufacturing system (150), The masking member (130) includes a first member (132) coupled to a corresponding one of the at least two mounting members (120) and a second member (134) coupling each of the first members (132) together.

8. The additively manufactured structure (140) of claim 7, wherein the masking member (130) covers at least a portion (122, 138) of each mounting member (120).

9. The additively manufactured structure (140) of claim 7, wherein the plurality of openings (104) are positioned in a spaced manner across the surface (106), and wherein each opening (104) includes a mounting member (120) at least partially positioned therein.

10. The additively manufactured structure (140) of claim 7, wherein the mounting members (120) extend outwardly from respective openings (104) along the surface (106) of the part (102).

11. A method comprising: first sequentially dispensing a fluid water-soluble material (160) layer by layer in a predetermined path to selectively generate a mounting member (120) at least partially located within at least two of a plurality of openings (104) in a surface (106) of a part (102); as well as secondly sequentially dispensing a fluid non-water-soluble material (162) layer by layer in a predetermined path to selectively generate a masking member (130) coupling at least two mounting members (120), The masking member (130) includes a first member (132) coupled to a corresponding one of the at least two mounting members (120) and a second member (134) coupling each of the first members (132) together.

12. The method of claim 11 , further comprising, before the first sequentially allocating: providing a bed of metal powder within the processing chamber; and Layers of metal powder on the metal powder bed are sequentially melted to generate the part (102) including the plurality of openings (104).

13. The method of claim 11, further comprising applying a coating (170) to the part (102), the at least two mounting members (120) preventing the coating (170) from entering the at least two openings of the plurality of openings (104).

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