Patent ID: 10471631

Abstract:
A method to form a part in an additive manufacturing system includes providing a melt pool configured to retain and dispense an electrically resistive consumable material and an array of channels in fluid communication with the melt pool. The method includes providing an array of channels in fluid communication with the melt pool, where each of the array of channels have a hollow electrically conductive nozzles wherein each of the array of nozzles is coupled to a distal end of one of the array of channels such that the consumable material can flow from the melt pool to each of the nozzles. The method includes providing a grid spaced from of the array of nozzle array wherein the grid defines a uniform ground potential, wherein the ground potential of the grid is substantially the same as a potential of the part being printed and the consumable material spaced from the grid. A plurality of drivers is in electric communication with the array of nozzles wherein each of the drivers is configured to modulate a voltage of a single nozzle of the array of nozzles wherein a difference in voltage from the array of nozzles to the ground potential allows passage of droplets of the consumable material to be ejected from each nozzle and pass through the grid, whereby electrostatic distortions of a drop from each nozzle selectively launches drops of support in response to changes of the potential of a nozzle by its driver such that consumable material is deposited in a layer by layer manner to form a portion of a mold for a part. The method includes depositing molten part material within the mold.