Hollow shell with internal baffle

摘要

A hollow thin walled shell with integral internal baffles is formed by a multilayer coating process. A series of mandrels is designed to be assembled to form the outer surface of the desired shell. The mandrel surfaces hidden during assembly include the areas intended to form the internal baffles. The mandrels are coated separately, assembled, and the assembly is given a continuous overcoating that holds the assembly together and provides the shell with mechanical integrity. The assembly is machined to remove all internal and external coated surfaces not intended to be included in the shell and the mandrel is dissolved or otherwise removed, leaving the thin coatings as the desired shell with baffles at the areas where the coated mandrel surfaces were hidden during assembly.