# US 12,109,656 B2 · Metal drop ejecting three-dimensional (3D) object printer and method of operation for forming metal support structures > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,109,656 B2 - Document ID: US12109656B2 - Status: Granted - Kind: B2 - Application number: 17/353,555 - Filed: 2021-06-21 - Published: 2022-12-22 - Granted: 2024-10-08 - Earliest claimed: 2021-06-21 - Assignees: Additive Technologies LLC - Applicants: Additive Technologies LLC - Inventors: Chu-Heng Liu; Paul J. McConville; Jason M. LeFevre; Douglas K. Herrmann; Seemit Praharaj - Web page: https://patentgrep.com/patent/US12109656B2 ## CPC - B23K 9/042: {Built-up welding on planar surfaces} - B22F 10/22: Direct deposition of molten metal - B22F 10/40: Structures for supporting workpieces or articles during manufacture and removed afterwards - B22F 10/85: for controlling or regulating additive manufacturing processes - B22F 12/53: Nozzles - B22F 12/70: Gas flow means - B22F 12/90: Means for process control, e.g. cameras or sensors - B23K 9/164: {making use of a moving fluid} - B23K 9/325: {Devices for supplying or evacuating shielding gas} - B23K 35/383: {mainly containing noble gases or nitrogen} - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 40/10: Pre-treatment - B33Y 50/02: for controlling or regulating additive manufacturing processes - B22F 10/43: characterised by material - B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING ## Abstract A three-dimensional (3D) metal object manufacturing apparatus is configured to increase the oxidation of ejected melted metal drops for the formation of metal support structures during manufacture of a metal object with the apparatus. The oxidation can be increased by either increasing a distance between the ejector head and a platform supporting the metal object or by providing an air flow transverse to the direction of movement of the melted metal drops, or both. ## Claims ### Claim 1 A metal drop ejecting apparatus comprising: an ejector head having a vessel with a receptacle within the vessel, the ejector head being configured to eject melted metal drops from the receptacle; a heater configured to heat the vessel while the vessel is in the ejector head to a temperature sufficient to melt solid metal within the receptacle of the vessel; a platform positioned to receive melted metal drops ejected from the receptacle of the vessel; a source of inert gas that is configured to provide a flow of inert gas surrounding the melted metal drops as the melted metal drops move toward the platform; and a controller being configured to: detect support structure layers in a digital model; generate machine-ready instructions that increase oxidation of the ejected melted metal drops after the melted metal drops have been ejected; and execute the generated machine-ready instructions to operate the metal drop ejecting apparatus to form support structures with oxidated melted metal drops during formation of a metal object with the metal drop ejecting apparatus. ### Claim 2 (depends on 1) The metal drop ejecting apparatus of claim 1 further comprising: at least one actuator operatively connected to at least one of the ejector head and the platform; and the controller being operatively connected to the at least one actuator, the controller being further configured to: execute the generated machine-ready instructions to operate the at least one actuator to increase a distance between the ejector head and the platform to increase oxidation of the ejected melted metal drops before the ejected melted metal drops land. ### Claim 3 (depends on 2) The metal drop ejecting apparatus of claim 2 further comprising: an air flow generator; and the controller being further configured to: execute the generated machine-ready instructions to operate the air flow generator to direct a flow of air transversely to a path of the ejected melted metal drops to increase oxidation of the ejected melted metal drops before the ejected melted metal drops land. ### Claim 4 (depends on 3) The metal drop ejecting apparatus of claim 3 further comprising: an oxygen source operatively connected to the air flow generator through a second valve; and the controller being further configured to: execute the generated machine-ready instructions to operate the humidifier to increase an amount of oxygen in the flow of air produced by the air flow generator. ### Claim 5 (depends on 3) The metal drop ejecting apparatus of claim 3 further comprising: a humidifier operatively connected to the air flow generator through a first valve; and the controller being further configured to: execute the generated machine-ready instructions to operate the humidifier to increase an amount of water vapor in the flow of air produced by the air flow generator. ### Claim 6 (depends on 5) The metal drop ejecting apparatus of claim 5 further comprising: an oxygen source operatively connected to the air flow generator through a second valve; and the controller being further configured to: execute the generated machine-ready instructions to operate the humidifier to increase an amount of oxygen in the flow of air produced by the air flow generator. ### Claim 7 (depends on 1) The metal drop ejecting apparatus of claim 1 further comprising: an air flow generator; and the controller being further configured to: execute the generated machine-ready instructions to operate the air flow generator to direct a flow of air transversely to a path of the ejected melted metal drops to increase oxidation of the ejected melted metal drops before the ejected melted metal drops land. ### Claim 8 (depends on 7) The metal drop ejecting apparatus of claim 7 further comprising: an oxygen source operatively connected to the air flow generator through a second valve; and the controller being further configured to: execute the generated machine-ready instructions to operate the second valve to increase an amount of oxygen in the flow of air produced by the air flow generator. ### Claim 9 (depends on 7) The metal drop ejecting apparatus of claim 7 further comprising: a humidifier operatively connected to the air flow generator through a first valve; and the controller being further configured to: execute the generated machine-ready instructions to operate the first valve to increase an amount of water vapor in the flow of air produced by the air flow generator. ### Claim 10 (depends on 9) The metal drop ejecting apparatus of claim 9 further comprising: an oxygen source operatively connected to the air flow generator through a second valve; and the controller being further configured to: execute the generated machine-ready instructions to operate the second valve to increase an amount of oxygen in the flow of air produced by the air flow generator. ### Claim 11 A method of operating a metal drop ejecting apparatus comprising: supplying inert gas around melted metal drops as the melted metal drops are ejected from a receptacle in an ejector head; detecting with a controller support structure layers in a digital model; generating machine-ready instructions with the controller that increase oxidation of ejected melted metal drops after the melted metal drops have been ejected from the receptacle within the ejector head; and executing the generated machine-ready instructions to operate the metal drop ejecting apparatus to form support structures with oxidated melted metal drops during formation of a metal object on a platform positioned to receive the melted metal drops ejected from the ejector head. ### Claim 12 (depends on 11) The method of claim 11 further comprising: executing the generated machine-ready instructions to operate at least one actuator operatively connected to one of the ejector head and the platform to increase a distance between the ejector head and the platform to increase oxidation of the ejected melted metal drops before the ejected melted metal drops land. ### Claim 13 (depends on 12) The method of claim 12 further comprising: executing the generated machine-ready instructions to operate an air flow generator to direct a flow of air transversely to a path of the ejected melted metal drops to increase oxidation of the ejected melted metal drops before the ejected melted metal drops land. ### Claim 14 (depends on 13) The method of claim 13 further comprising: executing the generated machine-ready instructions to operate a source of oxygen to increase an amount of oxygen in the flow of air produced by the air flow generator. ### Claim 15 (depends on 13) The method of claim 13 further comprising: executing the generated machine-ready instructions to operate a humidifier to increase an amount of water vapor in the flow of air produced by the air flow generator. ### Claim 16 (depends on 15) The method of claim 15 further comprising: executing the generated machine-ready instructions to operate a source of oxygen to increase an amount of oxygen in the flow of air produced by the air flow generator. ### Claim 17 (depends on 11) The method of claim 11 further comprising: executing the generated machine-ready instructions to operate an air flow generator to direct a flow of air transversely to a path of the ejected melted metal drops to increase oxidation of the ejected melted metal drops before the ejected melted metal drops land. ### Claim 18 (depends on 17) The method of claim 17 further comprising: executing the generated machine-ready instructions to operate a source of oxygen to increase an amount of oxygen in the flow of air produced by the air flow generator. ### Claim 19 (depends on 17) The method of claim 17 further comprising: executing the generated machine-ready instructions to operate a humidifier operatively connected to the air flow generator to increase an amount of water vapor in the flow of air produced by the air flow generator. ### Claim 20 (depends on 19) The method of claim 19 further comprising: executing the generated machine-ready instructions to operate a source of oxygen to increase an amount of oxygen in the flow of air produced by the air flow generator.