Microtextured nozzle for directed energy deposition with greater than 100 features per square millimeter

A system comprising:

• a fluidized powder source configured to provide a plurality of particles of a material;
• a material deposition head comprising:
• a body portion comprising a first end, a second end, and a first exterior surface extending from the first end to the second end;
• and
• a nozzle coupled to the body portion at or near the second end, wherein the nozzle defines a second exterior surface and a material delivery channel, wherein the material delivery channel is fluidically coupled to the fluidized powder source,
• wherein at least one of the first exterior surface or the second exterior surface comprises a microtextured surface configured to reduce a wettability of molten particles of the plurality of particles thereon, wherein the microtextured surface comprises a plurality of features, wherein a density of the plurality of features is greater than about 100 features per square millimeter.

A method comprising:

• positioning, to receive a surface texturing treatment, a material deposition head comprising:
• a body portion comprising a first end, a second end, and a first exterior surface extending from the first end to the second end;
• and
• a nozzle coupled to the body portion at or near the second end, wherein the nozzle defines a second exterior surface and a material delivery channel, wherein the material delivery channel is fluidically coupled to a fluidized powder source configured to provide a plurality of particles of a material;
• and
• forming a microtextured surface on at least one of the first exterior surface or the second exterior surface, wherein the microtextured surface is configured to reduce wetting of molten particles of the plurality of particles, wherein the microtextured surface comprises a plurality of features, wherein a density of the plurality of features is greater than about 100 features per square millimeter.