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 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 two solid metal moving mechanisms that are independently operated to move two different metals into the receptacle of a vessel in a melted metal drop ejecting apparatus. The ejector is operated to form object features with melted metal drops of one of the two different metals and to form support features with melted metal drops of the other of the two different metals. The thermal expansion coefficients of the two metals are sufficiently different that the support features easily separate from the object features after the object and support features cool.

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 method analyzes image data of a test pattern printed on an image receiving member by a printer to identify split inkjets in the printheads of the printer. The test pattern is formed by operating each inkjet of a printhead to form a dash and the areas of the dashes are compared to an average dash area to identify split inkjets. Firing signal parameters for the split inkjets are adjusted and subsequent firing signals are generated using the adjusted parameters. Image data of the pixels formed by the split inkjets are analyzed after the split inkjets have been operated using the adjusted firing signal parameters. If the pixel size for a split inkjets indicates that the split inkjet has been remediated, then the firing signal parameters are returned to their nominal values.

Abstract: A printing system comprises a print fluid deposition assembly, a media transport device, and an air flow control system. The print fluid deposition assembly comprises a carrier plate and a printhead arranged to eject a print fluid through an opening of the carrier plate to a deposition region. The media transport device holds a print medium against the movable support surface by vacuum suction and transports the print medium through the deposition region. The air flow control system comprises an air supply unit comprising air flow guide structure extending into the opening of the carrier plate between the carrier plate and the printhead to flow air through the opening. The air flow control system controls the air supply unit to selectively flow the air based on a location of a print medium relative to the printhead.

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 a removable vessel to reduce the time required for start-up procedures after the printer is serviced. The removable vessel is filled with solid metal that is heated to its melting temperature before the bulk wire is inserted into the vessel to commence printing operations. The melting of the solid metal in the removable vessel requires less time that the melting of an length of bulk wire adequate to produce a volume of melted metal suitable for printer operation. The solid metal in the removable vessel can be metal pellets, metal powder, or a solid metal insert.

Abstract: A three-dimensional (3D) object printer operates a radiation source to direct radiation emitted by the radiation source through a porous substrate at a first intensity insufficient to cure a material contained in the porous substrate and at a second intensity sufficient to cure the material after the emitted radiation has passed through the porous substrate. The material is applied to the porous substrate by one or more wipers.

Abstract: A printing system comprises a printhead to eject ink through an opening in a carrier plate to a deposition region. A print medium is held against a movable support surface by vacuum suction communicated through platen holes of a vacuum platen and transported through the deposition region. An airflow control system comprises upstream and downstream valves associated with the printhead, individually addressable channels for the vacuum platen, or both. The upstream and downstream valves are arranged to selectively block and allow airflow through an upstream side or a downstream side, respectively, of the opening in the carrier plate. Actuation of the upstream and downstream valves may be controlled based on a location of the print medium. The channels are arranged to selectively control the supply of vacuum suction to respectively corresponding columns of platen holes. Actuation of the channels may be controlled based on a size of the print medium.

Abstract: A printer having a pump which includes an inner cavity which retains a liquid metal printing material, and a nozzle, where the nozzle is configured to eject a plurality of liquid metal drops, an actuation coil configured to supply a pulse to the liquid metal to generate an electromagnetic force upon the liquid metal, where the actuation coil supplies a pulse at a first time varying current pulse, where the electromagnetic force causes the nozzle to eject a drop of liquid metal. The actuation coil also supplies a pulse at a second time varying current pulse, where the electromagnetic force is not sufficient to eject a drop of liquid. A method for metal jetting in a printer is also disclosed where differences between the temperature in an upper portion of the pump and the temperature in a lower portion of the pump are minimized.

Abstract: A three-dimensional (3D) metal object manufacturing apparatus is equipped with a liquid silicate application system to apply liquid silicate to a surface of a build platform prior to manufacture of a metal object. The liquid silicate layer is permitted to air dry and then the platform is heated to its operational temperature range for formation of a metal object with melted metal drops ejected by the apparatus. The liquid silicate layer forms a glassy, brittle 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 silicate 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 borate solution application system to either build support structures with a borate solution containing silica particles or to apply such a borate solution to a surface of a metal support structure prior to manufacture of a metal object feature that is supported by the support structure. The silica particles in the borate solution structure form a glassy, brittle structure on which the metal object feature is formed. This glassy, brittle structure is removed relatively easily from the object after the object is manufactured.

Abstract: A three-dimensional (3D) metal object manufacturing apparatus is equipped with a silicate slurry application system to build support structure layers with fused particulate suspended in the silicate slurry or to apply a layer of the silicate slurry to a metal support structure prior to manufacture of a metal object feature that is supported by either type of support structure. The fused particulate of a silicate support structure or a layer applied to a surface of a metal support structure forms a glassy, brittle layer on which the metal object feature is formed. This glassy, brittle structure is removed relatively easily from the object after the object is manufactured.

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 printing system comprises a printhead to eject a print fluid to a deposition region. Print media are held against a movable support surface via vacuum suction, and the movable support surface transports the print media through the deposition region. A vacuum plenum comprises a vacuum platen over which the movable support surface moves. The vacuum platen has platen holes that communicate the vacuum suction from the vacuum plenum to the movable support surface. An airflow restriction mechanism forms a high impedance zone in the vacuum platen, the high impedance zone comprising a subset of the platen holes. The airflow impedance through the high impedance zone is relatively high compared to the airflow impedance through another subset of the platen holes, which are part of a low impedance zone. The high impedance zone may be located near the printhead to reduce airflow through uncovered platen holes near the printhead.

Abstract: Alignment apparatuses include a frame and contact elements connected to the frame. The contact elements contact items that are to be transported in a processing direction relative to the frame. The contact elements are in permeant fixed positions relative to the frame, and do not move relative to the frame. Adjustable mounts are connected to the frame and move the frame in the processing direction and in a perpendicular cross-processing direction. A controller is electrically connected to the adjustable mounts, and the controller is adapted to control the adjustable mounts to simultaneously move the frame and all the contact elements in the cross-processing direction and the processing direction while rotating the frame. Methods laterally shift imaging on sheets that have had rotational correction performed by such alignment apparatuses.

Abstract: A dross extraction system for a printer is disclosed. The dross extraction system includes an ejector defining an inner cavity associated therewith, the inner cavity retaining a liquid printing material. The dross extraction system also includes an inlet coupled to the inner cavity and a conduit external to the ejector having a distal opening, positionable to contact the liquid printing material to attract dross therein, thereby extracting dross from the liquid printing material when a negative pressure is introduced between an internal volume of the conduit and the dross.

Abstract: A printing system comprises a printhead to eject a print fluid to a deposition region. A movable support surface, such as a belt, is used to transport print media through the deposition region, with the print media being held against the movable support surface by vacuum suction through holes in the movable support surface. A media registration device loads print media onto the movable support surface and registers the print media to a location of the movable support surface. The movable support surface comprises no-suction-regions in which the vacuum suction through the movable support surface is prevented. The no-suction regions extend across the width of the movable support surface in a cross-process direction and are arranged at predetermined intervals along the process direction. The control system causes the media registration device to register each of the print media relative to a respective one of the no-suction-regions.

Abstract: A three-dimensional (3D) metal object manufacturing apparatus is equipped with a solid graphite application device that forms graphite interfaces between support structures and portions of the metal object supported by the support structures. The graphite forming the graphite interfaces are applied to support structures by operating an actuator to move the graphite application to a surface of the support structure and move a graphite member within the device against the surface of the support structure.