Magnetohydrodynamic deposition of metal in manufacturing
First Claim
1. An additive manufacturing system, the additive manufacturing system comprising:
- a nozzle including a housing, one or more magnets, and electrodes, the nozzle defining a fluid chamber having an inlet region and a discharge region, the one or more magnets directing a magnetic field through the housing, and the electrodes defining at least a portion of a firing chamber in the fluid chamber between the inlet region and the discharge region, wherein electric current is conductible from the electrodes such that the electric current intersects the magnetic field in the firing chamber at a point substantially adjacent to a discharge orifice of the discharge region;
a robotic system mechanically coupled to the nozzle;
an electrical power source in electrical communication with the electrodes; and
a controller in electrical communication with the robotic system and the electrical power source, the controller configured tomove the robotic system to position the discharge region of the nozzle in a controlled three-dimensional pattern, andbased on the position of the discharge region along the controlled three-dimensional pattern, to actuate the electrical power source to deliver pulsed current to the electrodes to eject liquid metal from the discharge region to form a three-dimensional object, wherein a frequency of the pulsed current is less than about 5 kHz at a maximum speed of movement of the discharge region, and the frequency of the pulsed current is based on speed of movement of the nozzle.
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Accused Products
Abstract
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. The magnetohydrodynamic force can be pulsed to eject droplets of the liquid metal to provide control over accuracy of the object being fabricated. The pulsations can be applied in fluid chambers having high resonance frequencies such that droplet ejection can be effectively controlled over a wide range of frequencies, including high frequencies suitable for liquid metal ejection at rates suitable for commercially viable three-dimensional fabrication.
43 Citations
9 Claims
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1. An additive manufacturing system, the additive manufacturing system comprising:
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a nozzle including a housing, one or more magnets, and electrodes, the nozzle defining a fluid chamber having an inlet region and a discharge region, the one or more magnets directing a magnetic field through the housing, and the electrodes defining at least a portion of a firing chamber in the fluid chamber between the inlet region and the discharge region, wherein electric current is conductible from the electrodes such that the electric current intersects the magnetic field in the firing chamber at a point substantially adjacent to a discharge orifice of the discharge region; a robotic system mechanically coupled to the nozzle; an electrical power source in electrical communication with the electrodes; and a controller in electrical communication with the robotic system and the electrical power source, the controller configured to move the robotic system to position the discharge region of the nozzle in a controlled three-dimensional pattern, and based on the position of the discharge region along the controlled three-dimensional pattern, to actuate the electrical power source to deliver pulsed current to the electrodes to eject liquid metal from the discharge region to form a three-dimensional object, wherein a frequency of the pulsed current is less than about 5 kHz at a maximum speed of movement of the discharge region, and the frequency of the pulsed current is based on speed of movement of the nozzle. - View Dependent Claims (2)
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3. An additive manufacturing system, the additive manufacturing system comprising:
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a nozzle including a housing, one or more magnets, and electrodes, the nozzle defining a fluid chamber having an inlet region and a discharge region, the one or more magnets directing a magnetic field through the housing, and the electrodes defining at least a portion of a firing chamber in the fluid chamber between the inlet region and the discharge region, wherein electric current is conductible from the electrodes such that the electric current intersects the magnetic field in the firing chamber at a point substantially adjacent to a discharge orifice of the discharge region; a robotic system mechanically coupled to the nozzle; an electrical power source in electrical communication with the electrodes; and a controller in electrical communication with the robotic system and the electrical power source, the controller configured to move the robotic system to position the discharge region of the nozzle in a controlled three-dimensional pattern, and based on the position of the discharge region along the controlled three-dimensional pattern, actuate the electrical power source to deliver pulsed current to the electrodes to eject liquid metal from the discharge region to form a three-dimensional object, wherein the pulsed current has a frequency based on speed of movement of the nozzle. - View Dependent Claims (4, 5, 6, 7, 8, 9)
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Specification