Metal drop ejecting three-dimensional (3D) object printer and method of operation for forming support structures in 3D metal objects

A metal drop ejecting apparatus comprising:

• an ejector head configured to eject melted metal drops through a nozzle;
• a planar member positioned to receive melted metal drops ejected from the ejector head;
• and
• a controller operatively connected to the ejector head, the controller being configured to:
• move the ejector head over the planar member and operate the ejector head at a first ejection frequency to form a first line of spatially separated pillars on the planar member with metal drops ejected from the ejector head, the pillars in the spatially separated pillars are separated from one another by a predetermined distance;
• and
• move the ejector head over the first line of spatially separated pillars and operate the ejector head at a second ejection frequency and a first drop spacing to eject melted metal drops that form a continuous metal line over the first line of spatially separated pillars in a single pass, the second ejection frequency being different than the first ejection frequency.