Method for creating a free-form metal three-dimensional article using a layer-by-layer deposition of a molten metal

摘要

A method for the accurate formation of a three-dimensional article comprises providing a supply of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. The supply of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment mechanism which repels each droplet toward an axis extending through the alignment mechanism. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without the use of a mold of the shape of the three-dimensional article.