A pump assembly for use in an additive manufacturing system includes a viscosity pump having a first end and a second end wherein the first end has a cross sectional area greater than a cross sectional area of the second end. The viscosity pump has a conical shaped inner surface defining a pump chamber, an inlet proximate the first end and an outlet proximate the second end. The viscosity pump includes an impeller having an axis of rotation, where the impeller has a shaft positioned through the first end of the first housing and into the pump chamber. The impeller includes a distal tip-end at a distal end of the shaft wherein the impeller is configured to be axially displaced within the pump chamber of the viscosity pump parallel to the axis of rotation. An actuator is coupled to a proximal end of the impeller, wherein the actuator is configured to move the impeller parallel to the axis of rotation.

A pump assembly for use in an additive manufacturing system includes a viscosity pump having a first end and a second end wherein the first end has a cross sectional area greater than a cross sectional area of the second end. The viscosity pump has a conical shaped inner surface defining a pump chamber, an inlet proximate the first end and an outlet proximate the second end. The viscosity pump includes an impeller having an axis of rotation, where the impeller has a shaft positioned through the first end of the first housing and into the pump chamber. The impeller includes a distal tip-end at a distal end of the shaft wherein the impeller is configured to be axially displaced within the pump chamber of the viscosity pump parallel to the axis of rotation. An actuator is coupled to a proximal end of the impeller, wherein the actuator is configured to move the impeller parallel to the axis of rotation.

Atomization processes for manufacturing a metal powder or an alloy powder having a melting point comprising of about 50 Celsius to about 500 Celsius are provided herein. In at least one embodiment, the processes comprise providing a melt of a metal or an alloy having said melting point of about 50 Celsius to about 500 Celsius through a feed tube; diverting the melt at a diverting angle with respect to a central axis of the feed tube to obtain a diverted melt; directing the diverted melt to an atomization area; and providing at least one atomization gas stream to the atomization area. The atomization process can be carried out in the presence of water within an atomization chamber used for the atomization process. In at least one embodiment, the processes provide a distribution of powder with an average particle diameter under 20 microns with geometric standard deviation of lower than about 2.0.

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. Porosity of one or more predetermined portions of objects fabricated from an accumulation of liquid metal droplets ejected using magnetohydrodynamic force can be controlled to form interfaces between support structures and parts within the object. Higher porosity along the interfaces, as compared to porosity along the support structures and the parts, can be useful for facilitating separation of the parts from the support structures.

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. Porosity of one or more predetermined portions of objects fabricated from an accumulation of liquid metal droplets ejected using magnetohydrodynamic force can be controlled to form interfaces between support structures and parts within the object. Higher porosity along the interfaces, as compared to porosity along the support structures and the parts, can be useful for facilitating separation of the parts from the support structures.

Devices, systems, and methods are directed to applying magnetohydrodynamic forces to liquid metal to eject liquid metal from a nozzle along a controlled pattern, such as a controlled three-dimensional pattern as part of additive manufacturing of an object. Electrodes used to deliver electric current across a firing chamber of the nozzle are formed of the same material as the liquid metal being ejected from the nozzle. For example, respective interfaces between the electrodes and the liquid metal can be molten material. Forming the electrodes and the liquid metal of the same material can facilitate, for example, ejecting liquid metals having high melt temperatures.

Devices, systems, and methods are directed to applying magnetohydrodynamic forces to liquid metal to eject liquid metal from a nozzle along a controlled pattern, such as a controlled three-dimensional pattern as part of additive manufacturing of an object. Electrodes used to deliver electric current across a firing chamber of the nozzle are formed of the same material as the liquid metal being ejected from the nozzle. For example, respective interfaces between the electrodes and the liquid metal can be molten material. Forming the electrodes and the liquid metal of the same material can facilitate, for example, ejecting liquid metals having high melt temperatures.

Devices, systems, and methods are directed to the pneumatic ejection of liquid metal from a nozzle moving along a controlled three-dimensional pattern to fabricate a three-dimensional object through additive manufacturing. The metal is movable into the nozzle as a valve is actuated to control movement of pressurized gas into the nozzle. Such movement of metal into the valve as pressurized gas is being moved into the nozzle to create an ejection force on liquid metal in the nozzle can reduce or eliminate the need to replenish a supply of the metal in the nozzle and, therefore can facilitate continuous or substantially continuous liquid metal ejection for the fabrication of parts.

Devices, systems, and methods are directed to the pneumatic ejection of liquid metal from a nozzle moving along a controlled three-dimensional pattern to fabricate a three-dimensional object through additive manufacturing. The metal is movable into the nozzle as a valve is actuated to control movement of pressurized gas into the nozzle. Such movement of metal into the valve as pressurized gas is being moved into the nozzle to create an ejection force on liquid metal in the nozzle can reduce or eliminate the need to replenish a supply of the metal in the nozzle and, therefore can facilitate continuous or substantially continuous liquid metal ejection for the fabrication of parts.

Devices, systems, and methods are directed to applying magnetohydrodynamic forces to liquid metal to eject liquid metal from a nozzle along a controlled pattern, such as a controlled three-dimensional pattern as part of additive manufacturing of an object. A feeder system can provide a continuous or substantially continuous supply of a solid metal to the nozzle to facilitate a correspondingly continuous or substantially continuous process for ejecting liquid metal as part of a commercially viable manufacturing process.