Abstract: Devices, systems, and methods are directed to the pneumatic ejection of liquid metal from a nozzle moving along a controlled three-dimensional pattern to fabricate a three-dimensional object through additive manufacturing. The metal is movable into the nozzle as a valve is actuated to control movement of pressurized gas into the nozzle. Such movement of metal into the valve as pressurized gas is being moved into the nozzle to create an ejection force on liquid metal in the nozzle can reduce or eliminate the need to replenish a supply of the metal in the nozzle and, therefore can facilitate continuous or substantially continuous liquid metal ejection for the fabrication of parts.

Abstract: Devices, systems, and methods are directed to the pneumatic ejection of liquid metal from a nozzle moving along a controlled three-dimensional pattern to fabricate a three-dimensional object through additive manufacturing. The metal is movable into the nozzle as a valve is actuated to control movement of pressurized gas into the nozzle. Such movement of metal into the valve as pressurized gas is being moved into the nozzle to create an ejection force on liquid metal in the nozzle can reduce or eliminate the need to replenish a supply of the metal in the nozzle and, therefore can facilitate continuous or substantially continuous liquid metal ejection for the fabrication of parts.

Abstract: Devices, systems, and methods are directed to switching between pneumatically actuated ejection and electrically actuated ejection of liquid metal from a nozzle moving along a controlled three-dimensional pattern to fabricate a three-dimensional object. Electrically actuated ejection can be useful, for example, for delivering discrete droplets in areas of the object requiring a high degree of accuracy. Pneumatic ejection can be useful, for example, for delivering a stream of liquid metal from the nozzle to provide liquid metal rapidly to areas of the object that require less accuracy (e.g., an inner portion of the object). Accordingly, switching between pneumatically actuated ejection and electrically actuated ejection can facilitate accurate and rapid production of parts through additive manufacturing.

Abstract: Devices, systems, and methods are directed to adjusting a pneumatic circuit associated with pneumatic ejection of liquid metal from a nozzle as the nozzle moves along a controlled three-dimensional pattern to fabricate a three-dimensional object. The adjustment of the pneumatic circuit can facilitate adjusting a pressure profile within the nozzle as pressurized gas moves through the nozzle to eject, through pneumatic force, liquid metal from the nozzle. Through adjustment of the pneumatic circuit, characteristics of the liquid metal (e.g., size, shape, and flow rate) can be controlled to facilitate control over fabrication of the three-dimensional object.

Abstract: Devices, systems, and methods are directed to separating sediment from liquid metal ejected, through pneumatic force, from a nozzle moving along a controlled three-dimensional pattern to fabricate a three-dimensional object. The separation of the sediment from the liquid metal can reduce the likelihood that the nozzle will become clogged or otherwise degraded during fabrication of the three-dimensional object or over the course of fabrication of multiple objects. Accordingly, the separation of the sediment from the liquid metal can facilitate, for example, the use of pneumatic ejection of liquid metal for high volume production of parts.