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: An ejector of liquid material to form spherical particles includes a crucible for retaining liquid material, an orifice area defining at least one orifice, and an actuator responsive to a voltage signal for causing material to be ejected from the crucible through the orifice. A method comprises applying a voltage signal of a first type and a second type to the actuator, causing a material droplet of a first size and a second size to be ejected through the orifice. Alternately or in addition, the orifice area defines a first orifice having a first diameter and a second orifice having a second diameter different from the first diameter, whereby a signal causes a material droplet of a first size to be ejected through the first orifice and a material droplet of a second size to be ejected through the second orifice.

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 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 for ejecting a print material includes an actuator for applying a pressure to the print material, and further includes jetting assembly block that defines a pump chamber, a converging part (i.e., a narrowing taper), and a nozzle bore that ends or terminates in a nozzle from which a drop of the print material is ejected. An implementation can further include a throat and a diverging part that, together with the converging part, forms a venturi. The converging part results in an increase in a velocity of the print material and a decrease in pressure as the print material passes an supply port of a supply channel. The decrease in pressure can result in a replacement of at least a portion of the drop volume within the throat or the nozzle bore even before the drop is ejected from the nozzle.

Abstract: A jetting assembly for ejecting a print material includes an actuator for applying a pressure to the print material, and further includes jetting assembly block that defines a pump chamber, a converging part (i.e., a narrowing taper), and a nozzle bore that ends or terminates in a nozzle from which a drop of the print material is ejected. An implementation can further include a throat and a diverging part that, together with the converging part, forms a venturi. The converging part results in an increase in a velocity of the print material and a decrease in pressure as the print material passes an supply port of a supply channel. The decrease in pressure can result in a replacement of at least a portion of the drop volume within the throat or the nozzle bore even before the drop is ejected from the nozzle.

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 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 method of additive manufacturing includes jetting liquid material on a workpiece defining an uphill local surface and a downhill local surface. A printhead moves relative to the workpiece in a process direction, over the uphill local surface and the downhill local surface. Liquid material is jetted from the moving printhead onto the uphill local surface of the workpiece at a first predetermined spatial resolution. In a first approach, the printhead is controlled to refrain from jetting liquid material onto the downhill local surface of the workpiece. In a second approach, a local slope of the workpiece is determined, and a spatial resolution for jetting liquid material onto the local surface is determined as a function of the local slope.

Abstract: An ejector of liquid material to form spherical particles includes a crucible for retaining liquid material, an orifice area defining at least one orifice, and an actuator responsive to a voltage signal for causing material to be ejected from the crucible through the orifice. A method comprises applying a voltage signal of a first type and a second type to the actuator, causing a material droplet of a first size and a second size to be ejected through the orifice. Alternately or in addition, the orifice area defines a first orifice having a first diameter and a second orifice having a second diameter different from the first diameter, whereby a signal causes a material droplet of a first size to be ejected through the first orifice and a material droplet of a second size to be ejected through the second orifice.