A method for additive fabrication by 3D printing includes processing model data representing material transition boundaries of an object to be printed to form build data for use in controlling printing of a plurality of successive layers to form the object, the build data comprising, for each location of a plurality of locations in a two-dimensional arrangement, material transition data for representing heights of material transitions in a third dimension, and repeating for each layer of the plurality of successive layers, receiving surface height data representing a height of a partial fabrication of the object at respective locations of a plurality of locations on a surface of the partial fabrication for each location of the plurality of locations, using the height at the location to access the material transition data corresponding to the location in the build data, and using the material transition data to determine material to be deposited at that location, and causing emission of the determined material at each location of the plurality of locations, thereby causing printing of the layer.

A three-dimensional (3D) metal object manufacturing apparatus is equipped with a vacuum system and a hold-down plate to secure a metal foil to the hold-down plate during manufacture of a metal object. The melted metal drops ejected by the apparatus to form the object bond to the metal foil to form the base layer of the object. When the vacuum system is deactivated after manufacture of the object is complete, the object and foil are removed from the apparatus intact and the foil not part of the base layer is trimmed from the object.

A three-dimensional (3D) metal object manufacturing apparatus is equipped with a vacuum system and a hold-down plate to secure a metal foil to the hold-down plate during manufacture of a metal object. The melted metal drops ejected by the apparatus to form the object bond to the metal foil to form the base layer of the object. When the vacuum system is deactivated after manufacture of the object is complete, the object and foil are removed from the apparatus intact and the foil not part of the base layer is trimmed from the object.

A molten metal print deposition device includes a reservoir in fluid communication with a deposition head for controlled deposition of a molten metal print medium defined by molten feedstock, and a capillary structure adapted to maintain the molten feedstock from the melt reservoir in a fluidic state for directing and depositing the feedstock onto a substrate. A print medium is defined by an alloy heated to a fluid state in a temperature range defined by but above a liquidus and solidus. A thermal source and control circuit maintain the molten feedstock at a temperature above the liquidus of the print medium during deposition.

A molten metal print deposition device includes a reservoir in fluid communication with a deposition head for controlled deposition of a molten metal print medium defined by molten feedstock, and a capillary structure adapted to maintain the molten feedstock from the melt reservoir in a fluidic state for directing and depositing the feedstock onto a substrate. A print medium is defined by an alloy heated to a fluid state in a temperature range defined by but above a liquidus and solidus. A thermal source and control circuit maintain the molten feedstock at a temperature above the liquidus of the print medium during deposition.

A three-dimensional (3D) printer includes a nozzle and a camera configured to capture a real image or a real video of a liquid metal while the liquid metal is positioned at least partially within the nozzle. The 3D printer also includes a computing system configured to perform operations. The operations include generating a model of the liquid metal positioned at least partially within the nozzle. The operations also include generating a simulated image or a simulated video of the liquid metal positioned at least partially within the nozzle based at least partially upon the model. The operations also include generating a labeled dataset that comprises the simulated image or the simulated video and a first set of parameters. The operations also include reconstructing the liquid metal in the real image or the real video based at least partially upon the labeled dataset.

A laser-assisted microfluidics manufacturing process has been developed for the fabrication of additively manufactured structures. Roll-to-roll manufacturing is enhanced by the use of a laser-assisted electrospray printhead positioned above the flexible substrate. The laser electrospray printhead sprays microdroplets containing nanoparticles onto the substrate to form both thin-film and structural layers. As the substrate moves, the nanoparticles are sintered using a laser beam directed by the laser electrospray printhead onto the substrate.

A nozzle according to one embodiment has an inner surface and an outer surface, and is provided with a first passage through which an energy ray passes, and a second passage that is provided between the inner surface and the outer surface, and through which powder and fluid pass. The second passage includes a second open end on one end thereof in a first direction. A first surface that is one of the inner surface and the outer surface includes a first edge on one end thereof in the first direction. A second surface that is the other one of those includes a second edge on one end thereof in the first direction, and is distanced from the first edge toward the first direction. The fluid ejected from the second open end flows along the second surface, and separates at the second edge.

Provided is a method which includes a first layer formation step of forming a first layer by using a first composition that contains a constituent material powder, a first powder, and a binder of a three-dimensional shaped article; a second layer formation step of forming a second layer by using a second composition that contains a second powder and a binder; a degreasing step of a stack containing the first layer and the second layer; and a sintering step of the stack, a decomposition point of the first powder is higher than decomposition points of the binder of the first layer and the binder of the second layer, a decomposition point of the second powder is higher than the decomposition point of the first powder, and a sintering temperature of the constituent material powder is higher than the decomposition point of the second powder.

A method for producing a metal shaped article having a porous structure includes a mold formation step of forming a mold having a plurality of columnar structures extending from a substrate by performing a resin material supply step of supplying a liquid containing a resin material to a plurality of places of the substrate at intervals in two directions crossing each other, and a curing step of curing the liquid, a sintering target material supply step of supplying a sintering target material to the mold, a removal step of removing the substrate, a degreasing step of degreasing the columnar structures, and a sintering step of sintering the sintering target material.