A plasticizing apparatus for plasticizing a material to form a molten material includes a screw in a columnar shape having a groove formed face, in which a material flow channel including a groove portion to be supplied with the material is formed, and a barrel having a screw opposed face, which is a face opposed to the groove formed face, and in which a sending-out hole for sending out the molten material is formed at a center, and a heating portion heating the material. The material flow channel has a recess provided at a center of the groove formed face, and the groove portion extending in a spiral shape toward an outer circumference of the groove formed face from the recess, and a heat insulating portion having a lower thermal conductivity than an outer circumferential portion in the screw is provided in at least a part of an inner circumferential portion including the recess in the screw.

A caster assembly configured to process and store a material includes a reaction chamber, a storage assembly configured to store material processed in the reaction chamber, and a blower configured to process and store the material. The reaction chamber includes a vessel configured to hold the material in a melted state prior to processing and a powder generating assembly configured to receive the material from the melting vessel. The powder generating assembly includes a feeding chamber and a feeding device disposed at least partially within the feeding chamber. The feeding device includes at least one nozzle configured to inject inert fluid, where the fluid is a gas, liquid, or combination of the two into the feeding chamber and a material inlet through which the material is configured to flow into the feeding chamber to be exposed to the inert fluid, where the fluid is a gas, liquid, or combination of the two.

This disclosure pertains to a system, methods, and apparatus configured for generating singulated metal droplets and collecting powder metal. The system comprises crucible apparatus each including a crucible housing, a gas inlet, and an alloy nozzle. The crucible housing is operatively coupled to an induction heating element and power supply to provide induction heating of the crucible housing and electromagnetically levitate a mass of molten metal. The gas inlet is operatively coupled to a gas supply and configured to receive a pressurized gas pulse via the gas supply, the pressurized gas pulse being directed at the mass of molten metal. The alloy nozzle is configured to release a metal droplet singulated from the mass of molten level due to the pressurized gas pulse. The system includes a powder collection unit configured to collect powder from one or more dispensing channel configured to catch the falling singulated liquid metal droplet.

This disclosure pertains to a system, methods, and apparatus configured for generating singulated metal droplets and collecting powder metal. The system comprises crucible apparatus each including a crucible housing, a gas inlet, and an alloy nozzle. The crucible housing is operatively coupled to an induction heating element and power supply to provide induction heating of the crucible housing and electromagnetically levitate a mass of molten metal. The gas inlet is operatively coupled to a gas supply and configured to receive a pressurized gas pulse via the gas supply, the pressurized gas pulse being directed at the mass of molten metal. The alloy nozzle is configured to release a metal droplet singulated from the mass of molten level due to the pressurized gas pulse. The system includes a powder collection unit configured to collect powder from one or more dispensing channel configured to catch the falling singulated liquid metal droplet.

An ejector for a printing system is disclosed. The ejector body may include an internal cavity, a nozzle in communication with the internal cavity, one or more segmented solenoid coils wrapped at least partially around the ejector body, and a piston disposed within the internal cavity of the ejector body. A method of ejecting liquid from an ejector is also disclosed, including introducing a material for ejection into an ejector cavity. The method of ejecting liquid from an ejector may include advancing a piston configured for translational motion within an ejector towards an ejector nozzle which may further include de-energizing a first segment of a segmented solenoid wrapped partially around the ejector, energizing a second solenoid segment of a segmented solenoid wrapped partially around the ejector. The method of ejecting liquid from an ejector may also include ejecting a drop of the material for ejection from the ejector nozzle.

A caster assembly configured to process and store a material includes a reaction chamber, a storage assembly configured to store material processed in the reaction chamber, and a blower configured to process and store the material. The reaction chamber includes a vessel configured to hold the material in a melted state prior to processing and a powder generating assembly configured to receive the material from the melting vessel. The powder generating assembly includes a feeding chamber and a feeding device disposed at least partially within the feeding chamber. The feeding device includes at least one nozzle configured to inject inert fluid, where the fluid is a gas, liquid, or combination of the two into the feeding chamber and a material inlet through which the material is configured to flow into the feeding chamber to be exposed to the inert fluid, where the fluid is a gas, liquid, or combination of the two.

An ejector of liquid material to form spherical particles includes a crucible for retaining liquid material, an orifice area defining at least one orifice, and an actuator responsive to a voltage signal for causing material to be ejected from the crucible through the orifice. A method comprises applying a voltage signal of a first type and a second type to the actuator, causing a material droplet of a first size and a second size to be ejected through the orifice. Alternately or in addition, the orifice area defines a first orifice having a first diameter and a second orifice having a second diameter different from the first diameter, whereby a signal causes a material droplet of a first size to be ejected through the first orifice and a material droplet of a second size to be ejected through the second orifice.

The present invention relates to an iron-based alloy powder wherein the alloy comprises the elements Fe (iron), Cr (chrome) and Mo (molybdenum) and the iron-based alloy powder is produced by an ultra-high liquid atomization process comprising at least two stages as defined below.

A three-dimensional (3D) metal object manufacturing apparatus is equipped with a magnetic field generator to form a magnetic field selectively about a nozzle from which melted metal drops are ejected. The drops ejected in the presence of the magnetic field have their velocities reduced from the initial velocity at which they are ejected. The reduced velocity increases the time in flight of the drops before they impact their landing areas. The increased travel time enables the melted metal drops to oxidize sufficiently that they bond less tightly than the drops ejected without passing through the magnetic field. Thus, the apparatus can form metal support structures that adhere less tightly to the part portions of the object so they can be more easily removed after printing of the object.

In a method for jetting a droplet of an electrically conductive fluid, a Lorentz force is generated in the electrically conductive fluid. The Lorentz force is directed into an actuation direction. The actuation direction is a direction opposite to the droplet ejection direction. A jetting device is provided for printing a droplet of an electrically conductive fluid.