A method may comprise: placing a probe in a molten metal melt comprising a thixotropic metal alloy; injecting a gas into the molten metal melt to form a saturated slurry, the saturated slurry being at a temperature above a liquidus temperature of the thixotropic metal alloy after injecting the gas; removing the probe from the molten metal melt; and depositing the molten metal melt through an extruder of an additive manufacturing system.

A method may comprise: placing a probe in a molten metal melt comprising a thixotropic metal alloy; injecting a gas into the molten metal melt to form a saturated slurry, the saturated slurry being at a temperature above a liquidus temperature of the thixotropic metal alloy after injecting the gas; removing the probe from the molten metal melt; and depositing the molten metal melt through an extruder of an additive manufacturing system.

A three-dimensional (3D) metal object manufacturing apparatus is equipped with two solid metal moving mechanisms that are independently operated to move two different metals into the receptacle of a vessel in a melted metal drop ejecting apparatus. The ejector is operated to form object features with melted metal drops of one of the two different metals and to form support features with melted metal drops of the other of the two different metals. The thermal expansion coefficients of the two metals are sufficiently different that the support features easily separate from the object features after the object and support features cool.

A three-dimensional (3D) metal object manufacturing apparatus is equipped with two solid metal moving mechanisms that are independently operated to move two different metals into the receptacle of a vessel in a melted metal drop ejecting apparatus. The ejector is operated to form object features with melted metal drops of one of the two different metals and to form support features with melted metal drops of the other of the two different metals. The thermal expansion coefficients of the two metals are sufficiently different that the support features easily separate from the object features after the object and support features cool.

A method and apparatus are provided for producing a multicomponent feedstock being delivered through a print head of a 3D printer. Multiple component lengths are produced from separate feedstocks and are aligned to form the multicomponent feedstock which is fed into the print head for extrusion. The method includes providing at least two sources of feedstock of different material, feeding a distal end of a first feedstock along a feed path, cutting the first feedstock at a pre-determined length to provide a length of first feedstock having a proximal end. The method includes feeding a distal end of a second feedstock along the feed path and aligning the distal end of the second feedstock with the proximal end of the length of the first feedstock. The second feedstock is cut at a pre-determined length to provide a length of the second feedstock serially aligned with the length of first feedstock, to form a length of multicomponent feedstock. The length of multicomponent feedstock is fed into the print head.

A method and apparatus are provided for producing a multicomponent feedstock being delivered through a print head of a 3D printer. Multiple component lengths are produced from separate feedstocks and are aligned to form the multicomponent feedstock which is fed into the print head for extrusion. The method includes providing at least two sources of feedstock of different material, feeding a distal end of a first feedstock along a feed path, cutting the first feedstock at a pre-determined length to provide a length of first feedstock having a proximal end. The method includes feeding a distal end of a second feedstock along the feed path and aligning the distal end of the second feedstock with the proximal end of the length of the first feedstock. The second feedstock is cut at a pre-determined length to provide a length of the second feedstock serially aligned with the length of first feedstock, to form a length of multicomponent feedstock. The length of multicomponent feedstock is fed into the print head.

A method and apparatus are provided for producing a multicomponent feedstock being delivered through a print head of a 3D printer. Multiple component lengths are produced from separate feedstocks and are aligned to form the multicomponent feedstock which is fed into the print head for extrusion. The method includes providing at least two sources of feedstock of different material, feeding a distal end of a first feedstock along a feed path, cutting the first feedstock at a pre-determined length to provide a length of first feedstock having a proximal end. The method includes feeding a distal end of a second feedstock along the feed path and aligning the distal end of the second feedstock with the proximal end of the length of the first feedstock. The second feedstock is cut at a pre-determined length to provide a length of the second feedstock serially aligned with the length of first feedstock, to form a length of multicomponent feedstock. The length of multicomponent feedstock is fed into the print head.

A system and method for controlling an additive manufacturing system to form a multi-material component. Operating parameter values may be determined for the additive manufacturing system based on a first material and a second material used to form the multi-material component to ensure a requisite level of bonding between particles of a gradient between the first and second materials. Data or models for the first and second materials, along with observed data from a plurality of sample multi-material components formed from the first and second materials may be utilized to determine the operating parameter values. In some cases, the operating parameter values may be tuned to form a multi-material component having predetermined values for parameter objectives along the gradient of the multi-material component. The additive manufacturing system may be a selective laser melting system.

Methods for fabricating a multi-material composite structure are described. Methods for fabricating a multi-material composite structure include forming a first colloidal ink solution with a first material matrix, water, and a rheology modifying agent; forming a second colloidal ink solution with a second material matrix, water, and a rheology modifying agent; printing a first layer on a substrate using a first printing nozzle carrying the first colloidal ink solution; printing a second layer on top of the first layer using a second printing nozzle carrying the second colloidal ink solution; forming a 3D structure by printing a plurality of layers including the first layer and the second layer printed in an alternating pattern; and sintering the 3D structure to form the multi-material composite structure.

Methods for fabricating a multi-material composite structure are described. Methods for fabricating a multi-material composite structure include forming a first colloidal ink solution with a first material matrix, water, and a rheology modifying agent; forming a second colloidal ink solution with a second material matrix, water, and a rheology modifying agent; printing a first layer on a substrate using a first printing nozzle carrying the first colloidal ink solution; printing a second layer on top of the first layer using a second printing nozzle carrying the second colloidal ink solution; forming a 3D structure by printing a plurality of layers including the first layer and the second layer printed in an alternating pattern; and sintering the 3D structure to form the multi-material composite structure.