Abstract: A method of printing an internal bridge in a three-dimensional object includes depositing a plurality of drops of a printing material in a first direction to form a supported stepout onto an edge of a bridging layer, depositing a plurality of drops of the printing material to form an anchor layer adjacent to and in contact with a supported stepout, and depositing a plurality of drops of the printing material to form an unsupported stepout adjacent to an in contact with the supported stepout. A printing system for three-dimensional objects is also described, which is configured to perform the method of printing an internal bridge in a three-dimensional object.

Abstract: A method of operating a three-dimensional (3D) metal object manufacturing apparatus selects operational parameters for operation of the printer to form conductive metal traces on substrates with dimensions within appropriate tolerances and with sufficient conductive material to carry electrical currents without burning up or becoming too hot. The method identifies the material of the substrate and the bulk metal being melted for ejection and uses this identification data to select the operational parameters. Thus, the method can form conductive traces and circuits on a wide range of substrate materials including polymeric substrates, semiconductor materials, oxide layers on semiconductor materials, glass, and other crystalline materials.

Abstract: A method of forming a three-dimensional part is disclosed, including ejecting one or more drops of a print material at a first frequency to form a portion of a three-dimensional part. The method also includes ejecting one or more drops of the print material at a first line spacing, creating an unsupported overhang onto the three-dimensional printed part where the unsupported overhang is oriented at an angle of from 0 degrees to about 45 degrees relative to a print bed, and ejecting one or more drops of the print material at a second line spacing when creating at least a portion of the unsupported overhang. The method of forming a three-dimensional part further includes where drops are ejected at a first drop spacing when ejected at the first line spacing or at the second line spacing, and no portion of the unsupported overhang contacts the print bed.

Abstract: A method for operating a printer can include placing a first print material into a supply reservoir of the printer. The method also includes placing a second print material into the supply reservoir to combine with the first print material to form a diluted print material. The method also includes causing the diluted print material to exit the supply reservoir. Another method for operating a printer includes adding a first print material having a first melting point to a supply reservoir at a first rate. The method also includes adding a second print material having a second melting point to a supply reservoir at a second rate. The method for operating a printer also includes allowing the first print material and the second print material to combine to form a diluted print material. A printing system is also disclosed.

Abstract: A system for and a method of forming a bimetallic composite includes positioning a first metal in proximity to an ejector for jetting a material. The method of forming a bimetallic composite also includes ejecting one or more drops of the liquid material to form a layer of the liquid material onto a surface of the first metal. The method of forming a bimetallic composite also includes where the liquid material may include a second metal. The metal cladding system includes an ejector for jetting a liquid material, and a platform for conveying a component in proximity to the ejector.

Abstract: A method for printing a 3D part with a 3D printer includes ejecting drops of a build material from a nozzle of the 3D printer. A first plurality of the drops forms a perimeter of the 3D part, and a second plurality of the drops forms an infill of the 3D part. The method also includes controlling a parameter such that the parameter has a first value while the first plurality of the drops is ejected. The method also includes controlling the parameter such that the parameter has a second value while the second plurality of the drops is ejected, wherein the first and second values are different.

Abstract: A method for printing a 3D part includes decreasing a temperature of a build material in a nozzle of a 3D printer below a melting point of the build material, which causes the build material in the nozzle to transition from a liquid state to a solid state. The method also includes increasing the temperature of the build material in the nozzle above the melting point of the build material, which causes the build material in the nozzle to transition from the solid state to a sludgy state. An occlusion and the build material in the sludgy state are ejected from the nozzle.

Abstract: A three-dimensional (3D) metal object manufacturing apparatus is configured to increase the oxidation of ejected melted metal drops for the formation of metal support structures during manufacture of a metal object with the apparatus. The oxidation can be increased by either increasing a distance between the ejector head and a platform supporting the metal object or by providing an air flow transverse to the direction of movement of the melted metal drops, or both.

Abstract: A three-dimensional (3D) metal object manufacturing apparatus is operated to compensate for surface deviations of overhanging features differently than for non-overhanging features. The compensation technique used for the overhanging features depends on whether an edge of the overhanging feature being formed in a next layer has curved or sharp corners.

Abstract: The nozzles of a MHD liquid metal ejector/printhead can be clogged by contaminants in the liquid metal. Typically, these contaminants are in the form of small particles of aggregates of particles, such as metal oxides, that are insoluble in the liquid metal. Possible cleaning methods include mechanically removing the clogging material, such as by using a physical device to dislodge the clogging material and remove it; chemically removing the clogging material, such as by using selected chemicals/flux to chemically react with the clogging material; using ultrasound to break/remove the clogging material; and providing reversed and/or oscillating flow of material through the nozzle.

Abstract: A metal component is disclosed. The metal component has a first dimension greater than 5 mm, and a second dimension greater than 5 mm. The metal component may include where the alloy includes titanium, aluminum, vanadium, carbon, nitrogen, and oxygen. The alloy may include zirconium, titanium, copper, nickel, and beryllium. The metal component is not die-cast, melt-spun, or forged. An ejector and a method for jetting the metal component is also disclosed.

Abstract: A three-dimensional (3D) metal object manufacturing apparatus is equipped with a borate solution application system to apply a borate solution to a build platform surface prior to manufacture of a metal object. The borate solution is permitted to air dry before the platform is heated to its operational temperature range for formation of a metal object on the platform. The evaporation of the solvent from the borate solution causes the borate salt to form a glassy, brittle anhydrous borate layer on which the metal object is formed. This brittle layer is removed relatively easily with the object after the object is manufactured and the build platform is permitted to cool. The borate layer improves the wetting of the surfaces of build platforms made with non-wetting materials, such as oxidized steel, while also preventing metal-to-metal welds with wetting materials, such as tungsten or nickel.

Abstract: A three-dimensional (3D) metal object manufacturing apparatus is equipped with a movable directed energy source to melt hardened metal drops and form an oxidation layer. A metal support structure can be formed over the oxidation layer, an object feature can be formed over the oxidation layer, or both a metal support structure and an object feature can be formed over oxidation layers located at opposite sides of a metal support structure. The oxidation layers weakly attach the metal support structure to the object feature supported by the metal support structure so the support structure can be easily removed after manufacture of the object is complete.

Abstract: A three-dimensional (3D) object printer has an ejector head with a single nozzle that is fluidly connected to a plurality of orifices in an orifice plate of the ejector head. An ejection of material through the single nozzle is emitted through the plurality of orifices simultaneously. In one embodiment, some of the orifices are oriented at an angle to a normal to the plane of the orifice plate. A splicer of the printer that generates machine ready instructions for operation of the printer identifies a standoff distance between the orifice plate and a surface onto which drops are being ejected to achieve a target drop spacing for the drops ejected onto the surface. In this manner, a material density for structure within a layer can be achieved without needing to increase the ejection frequency significantly or requiring the printer to incorporate multiple ejector heads.

Abstract: An implementation of the present teachings includes a resistor structure for measuring a level of a print material such as a liquid metal print material within a reservoir of a printer such as a magnetohydrodynamic printer. The resistor structure includes a first electrode and a second electrode that are physically and electrically separated from each other. When positioned within the reservoir, the liquid metal physically contacts the first electrode and the second electrode. An electrical resistance between the first and second electrodes changes depending on the level of the print material within the reservoir. As the level of the print material decreases, the electrical resistance between the first electrode and the second electrode increases. The electrical resistance can be measured and used to determine a level of the print material within the reservoir.

Abstract: A three-dimensional (3D) printer is configured to introduce a liquid metal onto a first part and a second part while the first part and the second part are in contact with one another. The liquid metal subsequently solidifies to join the first part and the second part together to produce an assembly.

Abstract: A three-dimensional (3D) metal object manufacturing apparatus is equipped with an orifice cleaning system that removes metal drops that have adhered to a plate, an orifice in the plate, and a nozzle ejecting melted metal drops through the orifice during object forming operations. The orifice cleaning system includes an orifice cleaning tool that consists essentially of a soft carbon material, such as graphite. The orifice cleaning tool is configured with a handle that is gripped by an articulated arm to move the orifice cleaning tool against the plate, the orifice, and a portion of the nozzle at the orifice.