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.

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.

Devices, systems, and methods are directed to applying magnetohydrodynamic forces to liquid metal to eject liquid metal along a controlled pattern, such as a controlled three-dimensional pattern as part of additive manufacturing of an object. Electric current delivered to a meniscus of the liquid metal in a quiescent state can be directed to exert a pullback force on the liquid metal. The pullback force can be sufficient to draw the liquid metal, in the quiescent state, in a direction toward the nozzle to reduce the likelihood of unintended wetting of surfaces of the nozzle between uses of the nozzle.

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.

A method of manufacturing an additively manufactured component may comprise operating an additive manufacturing machine to form a first structure including an elongate portion having a blind design surface, operating the additive manufacturing machine to form a removal tool proximate the blind design surface, wherein the blind design surface and the removal tool are at least partially enclosed by and in contact with a support material, and translating the removal tool along the blind design surface to separate a portion of the support material from the blind design surface.

A method of manufacturing an additively manufactured component may comprise operating an additive manufacturing machine to form a first structure including an elongate portion having a blind design surface, operating the additive manufacturing machine to form a removal tool proximate the blind design surface, wherein the blind design surface and the removal tool are at least partially enclosed by and in contact with a support material, and translating the removal tool along the blind design surface to separate a portion of the support material from the blind design surface.

A build plate for an additive manufacturing device and methods for the same are provided. The build plate may include a base and a sacrificial plate coupled with the base. The etch rate of the sacrificial plate in an etchant may be greater than an etch rate of the base in the etchant. A method for separating a 3D printed article supported on the build plate may include contacting the sacrificial plate with the etchant.

A build plate for an additive manufacturing device and methods for the same are provided. The build plate may include a base and a sacrificial plate coupled with the base. The etch rate of the sacrificial plate in an etchant may be greater than an etch rate of the base in the etchant. A method for separating a 3D printed article supported on the build plate may include contacting the sacrificial plate with the etchant.

An apparatus for dispensing build powder and support powder, in a sequence of layers, and having a frame and a container. Also, a build powder pourer is at least partially filled with build powder and a support powder pourer at least partially filled with support powder, each of the pourers having a dispensing opening and a dispensing plug, controllably covering the dispensing opening. Further, a pourer-movement and dispensing plug-actuating assembly is supported by the frame over the container and includes a movement element that is selectively attachable to the build powder pourer and alternately to the support powder pourer and also capable to controllably move an attached pourer in three orthogonal dimensions and to control the dispensing plug. In addition, at least one docking station for holding a first one of the pourers; and a computing assembly controls the pourer-movement and dispensing plug-actuating assembly to create a target shape.

An apparatus for dispensing build powder and support powder, in a sequence of layers, and having a frame and a container. Also, a build powder pourer is at least partially filled with build powder and a support powder pourer at least partially filled with support powder, each of the pourers having a dispensing opening and a dispensing plug, controllably covering the dispensing opening. Further, a pourer-movement and dispensing plug-actuating assembly is supported by the frame over the container and includes a movement element that is selectively attachable to the build powder pourer and alternately to the support powder pourer and also capable to controllably move an attached pourer in three orthogonal dimensions and to control the dispensing plug. In addition, at least one docking station for holding a first one of the pourers; and a computing assembly controls the pourer-movement and dispensing plug-actuating assembly to create a target shape.