Patent ID: 7704565

Claim:
A method of making a layered component with an improved surface finish by a shape metal deposition process, the method comprising the steps of: discriminating a first set of boundary vectors on an exterior portion of the component from a second set of raster vectors on an interior portion of the component; and, depositing a layer of metal material based on the boundary and raster vectors discriminated at different rates, wherein the material is deposited on the exterior portion at a high resolution and a slow rate, and the material is deposited on the interior portion at a low resolution and a fast rate such that the rate of deposition of the material on the interior portion is two or more times greater than the rate of deposition of the material on the exterior portion, and further wherein the layered component has a surface roughness of between about 64 roughness height rating (rhr) to about 125 roughness height rating (rhr).