Singulated liquid metal droplet generator

A method for generating singulated liquid metal droplets utilizing a crucible having a gas inlet, a plurality of coils, and an alloy nozzle, the method comprising:

• providing a mass of metal wire into the crucible;
• inductively heating, utilizing the plurality of coils, the crucible thereby melting the mass of metal wire and electromagnetically levitating the mass of molten metal;
• and
• providing a pressurized gas pulse into the mass of molten metal via a gas inlet of the crucible and simultaneously lowering the levitation force thereby pushing out a singulated liquid metal droplet from the alloy nozzle, wherein the alloy nozzle includes one or more gas flow channels configured to assist in levitation of the mass of molten metal.

A system for generating singulated metal droplets and collecting powder metal, the system comprising:

• one or more crucible apparatus comprising:
• a crucible housing operatively coupled to induction heating coils configured to generate heat to provide induction heating of the crucible housing and electromagnetically levitate a mass of molten metal;
• a gas inlet configured to receive a pressurized gas pulse, the pressurized gas pulse being directed at the mass of molten metal;
• and
• an alloy nozzle configured to release a singulated liquid metal droplet singulated from the mass of molten metal due to the pressurized gas pulse directed at the mass of molten metal, wherein the alloy nozzle includes one or more gas flow channels configured to assist in levitation of the mass of molten metal;
• an induction power supply coupled to the induction heating element configured to supply power for inductive heating;
• a gas supply configured to provide a pressurized gas from the pressurized gas pulse;
• a gas chamber including the one or more crucibles apparatus;
• one or more dispensing channels that each correspond to the one or more crucible apparatus, wherein each of the one of more dispensing channels receive powder from one of the one or more crucible apparatus;
• and
• a powder collection unit configured to collect powder from the dispensing channel, the powder corresponding to a singulated liquid metal droplet.