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 an axis perpendicular to the orifice plate. This configuration enables a structure to be formed with a predetermined material density without needing to increase the ejection frequency significantly or requiring the printer to incorporate multiple ejector heads.

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: A method for operating a three-dimensional (3D) metal object manufacturing apparatus selects operational parameters for operation of the printer to form vias in substrates. The method identifies the bulk metal being melted for ejection and uses this identification data to select the operational parameters. The method identifies the via holes in the substrate and operates an actuator to position an ejector opposite the via holes to eject drops of melted bulk metal toward the via holes to fill the via holes.

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 three-dimensional (3D) metal object manufacturing apparatus selects operational parameters for operation of the printer to form vias in substrates. The apparatus identifies the bulk metal being melted for ejection and uses this identification data to select the operational parameters. The apparatus identifies the via holes in the substrate and positions an ejector opposite the via holes to eject drops of melted bulk metal toward the via holes to fill the via holes.

Abstract: 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 apparatus 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 apparatus 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 three-dimensional (3D) printer includes an ejector and a coil wrapped partially around the ejector. The 3D printer also includes a power source configured to transmit voltage pulses to the coil. The 3D printer causes one or more drops of the liquid to be jetted out of the nozzle, and a substrate configured to support the one or more drops and advance along a path defined by one or more arcuate contours, where the one or more arcuate contours define a first layer of a strut. One or more struts are printed from the first layer of the strut to a node of each strut. The one or more struts are printed from a first layer to a node and combine to fabricate a lattice structure including one or more vertical struts and/or one or more angled struts wherein each strut intersects with another strut at a node.

Abstract: An apparatus for additive manufacturing having a body; a plurality of articulated arms, each having a jointed connection to the body opposite a free end, the plurality of articulated arms movable relative to each other and the plurality of articulated arms having opposable motions about the jointed connection; an extruder at the free end of each of the plurality of articulated arms, the extruder having an extruder nozzle extending from the free end; and at least one cooling nozzle extending from the free end of each of the plurality of articulated arms.

Abstract: A method operates a three-dimensional (3D) metal object manufacturing system to compensate for errors that occur during object formation. In the method, thermal image data and dimensional image data of a metal object being formed by the 3D metal object manufacturing system is generated prior to completion of the metal object. Thermal conditions are identified from these data and compared to predetermined ranges corresponding to the identified thermal conditions to identify one or more errors. For identified errors outside a corresponding predetermined difference range, the method performs an error compensation technique. The error compensation includes modification of a surface data model, modification of machine-ready instructions, or operation of a subtractive device.

Abstract: A three-dimensional (3D) metal object manufacturing apparatus selects operational parameters for operation of the printer to form vias in substrates. The apparatus identifies the bulk metal being melted for ejection and uses this identification data to select the operational parameters. The apparatus identifies the via holes in the substrate and positions an ejector opposite the via holes to eject drops of melted bulk metal toward the via holes to fill the via holes.

Abstract: A three-dimensional (3D) printer includes an ejector and a coil wrapped at least partially around the ejector. The 3D printer also includes a power source configured to transmit voltage pulses to the coil. The 3D printer includes a computing system causing one or more drops of the liquid to be jetted out of the nozzle, and a vibrational source configured to transmit vibrational energy towards the printing material. The frequency of the vibrational energy may be dynamically modulated as a 3D object is formed by the 3D printer, and may be directly or indirectly applied to the printing material or 3D object. The vibrational source may include a piezoelectric source, ultrasonic source, a focused acoustic energy source, a laser vibrational source, or combinations thereof.

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: A three-dimensional (3D) printer includes an ejector and a coil wrapped at least partially around the ejector. The 3D printer also includes a power source configured to transmit voltage pulses to the coil. The 3D printer includes a computing system causing one or more drops of the liquid to be jetted out of the nozzle, and a substrate configured to support the one or more drops and advance along a path defined by one or more arcuate contours, where the one or more arcuate contours define a first layer of a strut. One or more struts are printed from the first layer of the strut to a node of each strut. The one or more struts are printed from a first layer to a node and combine to fabricate a lattice structure including one or more vertical struts and/or one or more angled struts wherein each strut intersects with another strut at a node.

Abstract: A three-dimensional (3D) printer includes an ejector and a coil wrapped at least partially around the ejector. The 3D printer also includes a power source configured to transmit voltage pulses to the coil. The 3D printer also includes a computing system configured to cause the power source to transmit the voltage pulses to the coil in intermittent bursts. The voltage pulses in each burst occur at a burst frequency from about 60 Hz to about 2000 Hz. The coil causes a drop of printing material to be jetted through a nozzle of the ejector in response to each voltage pulse. The drops generated in response to the voltage pulses in each burst land at substantially a same location in a horizontal plane.

Abstract: An approach to printing a nickel precursor ink on a wide range of substrates for electronics and magnetic applications is disclosed. The nickel ink reduces to elemental nickel following heating. The ink was printed using an ultrasonic aerosol printing technique. By sintering the nickel precursor ink in the presence of a homogeneous magnetic field, the reduced nickel complex formed continuously aligned nickel nanofibers axially aligned with the direction of the magnetic field. The fabrication of aligned interlayered nanofiber films provides opportunities to produce structures with enhanced isotropic electrical and magnetic properties. The resistivity of the film was found to be as low as 0.56 m?·cm, and the saturation magnetization was measured to be 30 emu/g, which is comparable to bulk Ni. Magnetic anisotropy was induced with an easy axis along the direction of the applied magnetic field with soft magnetic properties.

Abstract: 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 apparatus 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 apparatus 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 operates a three-dimensional (3D) metal object manufacturing system to compensate for errors that occur during object formation. In the method, thermal image data and dimensional image data of a metal object being formed by the 3D metal object manufacturing system is generated prior to completion of the metal object. Thermal conditions are identified from these data and compared to predetermined ranges corresponding to the identified thermal conditions to identify one or more errors. For identified errors outside a corresponding predetermined difference range, the method performs an error compensation technique. The error compensation includes modification of a surface data model, modification of machine-ready instructions, or operation of a subtractive device.

Abstract: An approach to printing a nickel precursor ink on a wide range of substrates for electronics and magnetic applications is disclosed. The nickel ink reduces to elemental nickel following heating. The ink was printed using an ultrasonic aerosol printing technique. By sintering the nickel precursor ink in the presence of a homogeneous magnetic field, the reduced nickel complex formed continuously aligned nickel nanofibers axially aligned with the direction of the magnetic field. The fabrication of aligned interlayered nanofiber films provides opportunities to produce structures with enhanced isotropic electrical and magnetic properties. The resistivity of the film was found to be as low as 0.56 m?·cm, and the saturation magnetization was measured to be 30 emu/g, which is comparable to bulk Ni. Magnetic anisotropy was induced with an easy axis along the direction of the applied magnetic field with soft magnetic properties.