Abstract: A method operates a three-dimensional (3D) metal object manufacturing system to compensate for displacement errors that occur during object formation. In the method, image data of a metal object being formed by the 3D metal object manufacturing system is generated prior to completion of the metal object and compared to original 3D object design data of the object to identify one or more displacement errors. For the displacement errors outside a predetermined difference range, the method modifies machine-ready instructions for forming metal object layers not yet formed to compensate for the identified displacement errors and operates the 3D metal object manufacturing system using the modified machine-ready instructions.

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.

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 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 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.

Abstract: A method includes ejecting a plurality of drops of a build material from a nozzle of a 3D printer. The build material cools and solidifies after being ejected to form a 3D object. The method also includes controlling an oxidation of the drops, the 3D object or both to create different oxidation levels in first and second portions of the 3D object.

Abstract: A three-dimensional (3D) printer includes an ejector and a heating element configured to heat a solid printing material in the ejector, thereby causing the solid printing material to change to a liquid printing material within the ejector. The 3D printer also includes a coil wrapped at least partially around the ejector. The 3D printer also includes a power source configured to supply one or more pulses of power to the coil, which cause one or more drops of the liquid printing material to flow out of the ejector through a nozzle of the ejector. The 3D printer also includes a gas-controlling device configured to control a gas in the 3D printer.

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) 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 jetting assembly that can be used to print a high-temperature print material such as a metal or metal alloy, an aqueous ink, or another material, includes an actuator for heating a gas such as a non-volatile gas within a gas cavity. The actuator rapidly heats the gas within the gas cavity, which rapidly increases a volume of the gas, thereby applying a pressure to the print material within an expansion channel that is in fluid communication with the gas cavity. In turn, the print material within the expansion channel applies a pressure to the print material within a nozzle bore, which forces a drop of the print material from a nozzle. The jetting assembly further includes a supply inlet that supplies the print material to the expansion chamber and the nozzle bore, for example, from a reservoir.

Abstract: A method for printing a structure, the structure including a plurality of pillars. The method for printing can include ejecting only a first drop of a print material such as a liquid metal sequentially at each of a plurality of pillar locations, then ejecting only a second drop of the print material sequentially onto the first drop at each of the plurality of print locations. Additional drops can be ejected at two or more of the pillar locations to form the plurality of pillars. Ejecting only a first drop at each pillar location allows the first drop to cure (i.e., cool or dry) before ejecting the second drop. The printer continues printing while the drops cure, thus improving processing efficiency and increasing production throughput.

Abstract: A jetting assembly that can be used to print a high-temperature print material such as a metal or metal alloy, an aqueous ink, or another material, includes an actuator for heating a gas such as a non-volatile gas within a gas cavity. The actuator rapidly heats the gas within the gas cavity, which rapidly increases a volume of the gas, thereby applying a pressure to the print material within an expansion channel that is in fluid communication with the gas cavity. In turn, the print material within the expansion channel applies a pressure to the print material within a nozzle bore, which forces a drop of the print material from a nozzle. The jetting assembly further includes a supply inlet that supplies the print material to the expansion chamber and the nozzle bore, for example, from a reservoir.

Abstract: A method for printing a structure, the structure including a plurality of pillars. The method for printing can include ejecting only a first drop of a print material such as a liquid metal sequentially at each of a plurality of pillar locations, then ejecting only a second drop of the print material sequentially onto the first drop at each of the plurality of print locations. Additional drops can be ejected at two or more of the pillar locations to form the plurality of pillars. Ejecting only a first drop at each pillar location allows the first drop to cure (i.e., cool or dry) before ejecting the second drop. The printer continues printing while the drops cure, thus improving processing efficiency and increasing production throughput.

Abstract: A method operates a three-dimensional (3D) metal object manufacturing system to compensate for displacement errors that occur during object formation. In the method, image data of a metal object being formed by the 3D metal object manufacturing system is generated prior to completion of the metal object and compared to original 3D object design data of the object to identify one or more displacement errors. For the displacement errors outside a predetermined difference range, the method modifies machine-ready instructions for forming metal object layers not yet formed to compensate for the identified displacement errors and operates the 3D metal object manufacturing system using the modified machine-ready instructions.

Abstract: A three-dimensional (3D) printer includes an ejector and a heating element configured to heat a solid printing material in the ejector, thereby causing the solid printing material to change to a liquid printing material within the ejector. The 3D printer also includes a coil wrapped at least partially around the ejector. The 3D printer also includes a power source configured to supply one or more pulses of power to the coil, which cause one or more drops of the liquid printing material to flow out of the ejector through a nozzle of the ejector. The 3D printer also includes a gas-controlling device configured to control a gas in the 3D printer.

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.