There is disclosed a method of printing onto the surface of a substrate, which method comprises i) coating a donor surface with a monolayer of particles, ii) treating the substrate surface to render at least selected regions tacky, and iii) contacting the substrate surface with the donor surface to cause particles to transfer from the donor surface only to the tacky regions of the substrate surface. After printing on a substrate, the donor surface returns to the coating station where the continuity of the monolayer is restored by recovering with fresh particles the regions of the donor surface exposed by the transfer of particles to the substrate.

An ultrasonic atomization material applicator includes a material applicator with at least one transducer and an array plate with an array of micro-applicators. Each of the micro-applicators has a material inlet, a reservoir, and a micro-applicator plate with a plurality of apertures. At least one supply line is in communication with the micro-applicators and configured to supply at least one material to each of the micro-applicators. The at least one ultrasonic transducer is mechanically coupled to the at least one array of micro-applicators and configured to vibrate the at least one array of micro-applicators such that atomized droplets of the at least one material are ejected from each of the micro-applicators. A movement device configured to cyclically move the at least one array of micro-applicators back and forth about at least one axis of the at least one array of micro-applicators can be included.

A head is disclosed for use with a continuous manufacturing system. The head may have a housing configured to receive a matrix and a continuous fiber, and a diverter located at an end of the housing. The diverter may be configured to divert radially outward a matrix-coated fiber. The head may also include a cutoff having an edge configured to press the matrix-coated fiber against the diverter.

A material applicator includes an array plate and at least one ultrasonic transducer mechanically coupled to the array plate. The array plate includes a plurality of micro-applicators and each of the micro-applicators has a material inlet, a reservoir, and a micro-applicator plate in mechanical communication with the at least one ultrasonic transducer. Each of the plurality of micro-applicator plates has a plurality of apertures and the at least one ultrasonic transducer is configured to vibrate each of the plurality of micro-applicator plates such that at least one material is ejected through the plurality of apertures as atomized droplets. At least one ultraviolet light source is positioned adjacent to the plurality of micro-applicators and the at least one UV light source is configured to irradiate the atomized droplets ejected through the plurality of apertures.

Systems and methods that provide or restore a coating to a component are provided. The systems and methods utilized an atomizing spray device. A gas and a slurry that comprises fluid and ceramic particles are supplied to the atomizing spray device. The slurry and gas are discharged from the spray device to form two-phase droplets. The fluid within the droplets evaporates to prevent the fluid from becoming part of the coating as the droplets traverse through the air and prior to impacting the surface of the component.

Plasma nozzle includes a nozzle body arranged to engage with a thermal spray gun. The nozzle body includes an axial through bore having up-stream input orifice and a down-stream nozzle exit, at least one material injector positioned between the up-stream input orifice and the nozzle-exit, said at least one material injector being configured to introduce a feedstock material into a gas flow passing through the axial through bore and at least one gas injector configured to introduce a shroud gas flow into the axial through bore and being located at a position up-stream of said at least one material injector.

An apparatus for applying a coating to a substrate includes a base, an applicator, and a quick-connect connector. The base includes a fluid conduit. The applicator includes at least one actuator and an array of nozzle plates. Each nozzle plate defines at least one aperture. The at least one actuator is configured to oscillate the nozzle plates to eject fluid from the apertures. The quick-connect connector couples the fluid conduit to the applicator for fluid communication therebetween.

In one example, a liquid mixture nozzle for flowing a liquid mixture therethrough includes a body having a flow inlet and a flow outlet. The flow inlet is configured to couple to a first piece of piping and the flow outlet is configured to couple to a second piece of piping. The liquid mixture nozzle also includes a converging section having a decreasing diameter positioned adjacent the flow inlet, an orifice positioned at a narrow end of the converging section, an intermediate section having a constant diameter positioned adjacent the orifice, a diverging section having an increasing diameter positioned adjacent the intermediate section and the flow outlet.

An apparatus is disclosed for coating a surface that is movable relative to the apparatus with a layer of metallic particles or particles having a metal-like appearance and reflectivity, the particles adhering more strongly to the surface than to one another. The apparatus comprises at least one spray head for directly or indirectly applying to the surface a fluid stream within which the particles are suspended, a housing surrounding the spray head(s) and defining an interior plenum for confining the fluid stream, the housing having a rim adjacent the surface that is configured to prevent egress of particles from a sealing gap defined between the rim of the housing and the surface to be coated, and a suction source connected to the housing to extract from the plenum the sprayed fluid and particles suspended in the sprayed fluid. In operation, the suction source extracts substantially all particles that are not in direct contact with the surface, so as to leave only a substantially single particle layer adhering to the surface on exiting the apparatus.

A method of controlling application of material onto a substrate includes ejecting atomized droplets from an array of micro-applicators while the array of micro-applicators cyclically moves about at least one axis. The atomized droplets from each of the plurality of micro-applicators overlap with atomized droplets from adjacent micro-applicators and a diffuse overlap of deposited atomized droplets from adjacent micro-applicators is provided on a surface of the substrate. The array of micro-applicators cyclically rotates back and forth around the at least one axis and/or moves back and forth parallel to the at least one axis. For example, the at least one axis can be a central axis of the array of micro-applicators, a length axis of the array of micro-applicators, a width axis of the array of micro-applicators, and the like. Also, the array of micro-applicators can be part of an ultrasonic material applicator used to paint vehicles.