# US 12,179,267 B2 · Metal printing and additive manufacturing apparatus > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,179,267 B2 - Document ID: US12179267B2 - Status: Granted - Kind: B2 - Application number: 17/847,793 - Filed: 2022-06-23 - Published: 2022-12-29 - Granted: 2024-12-31 - Earliest claimed: 2021-06-23 - Applicants: Michael A Perrone - Inventors: Michael A Perrone - Web page: https://patentgrep.com/patent/US12179267B2 ## CPC - B22F 10/22: Direct deposition of molten metal - B22F 10/30: Process control - B22F 10/368: Temperature or temperature gradient, e.g. temperature of the melt pool - B22F 12/53: Nozzles - B22F 12/57: Metering means - B22F 12/60: Planarisation devices; Compression devices - B22F 12/70: Gas flow means - B22F 12/90: Means for process control, e.g. cameras or sensors - B22F 3/11: Making porous workpieces or articles - B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - 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 molten metal print deposition device includes a reservoir in fluid communication with a deposition head for controlled deposition of a molten metal print medium defined by molten feedstock, and a capillary structure adapted to maintain the molten feedstock from the melt reservoir in a fluidic state for directing and depositing the feedstock onto a substrate. A print medium is defined by an alloy heated to a fluid state in a temperature range defined by but above a liquidus and solidus. A thermal source and control circuit maintain the molten feedstock at a temperature above the liquidus of the print medium during deposition. ## Claims ### Claim 1 A molten metal print deposition device, comprising a reservoir in fluid communication with a deposition head for controlled deposition of a print medium defined by molten feedstock; a capillary structure adapted to maintain the molten feedstock from the melt reservoir in a fluidic state for directing and depositing the feedstock onto a substrate; and a thermal source for maintaining the molten feedstock at a temperature above the liquidus of the print medium during deposition, the capillary structure further including a plurality of elongated strands, the strands formed from a material having a melting point based on a composition of the feedstock. ### Claim 2 (depends on 1) The device of claim 1 further comprising strands formed from a material based on a wettability of the molten feedstock and on a resistance to solubility by the molten feedstock. ### Claim 3 (depends on 1) The device of claim 1 further comprising: a control circuit for heating the reservoir; a temperature sensor connected to the control circuit and in communication with the reservoir; and melting logic for heating the reservoir based on a temperature signal from the temperature sensor and a thermal differential of the molten feedstock during deposition. ### Claim 4 (depends on 1) The device of claim 1 further comprising: a print bed, the print bed maintained at a temperature below a solidus of the print medium; and an actuator adapted for disposing the capillary structure relative to the print bed for directing a position of the print medium deposited onto the print bed. ### Claim 5 (depends on 1) The device of claim 1 wherein the thermal source is configured for maintaining a thermal gradient of the print medium between the reservoir to the substrate to accommodate a cooling effect while maintaining a temperature above the liquidus of the print medium. ### Claim 6 (depends on 1) The device of claim 1 further comprising an atmospheric enclosure around a print volume defined by an exit of the capillary structure for depositing the print medium and a print bed accumulating the deposited print medium, the atmospheric enclosure having an oxygen mitigation control for reducing oxygen present in the print volume. ### Claim 7 (depends on 6) The device of claim 6 wherein the oxygen mitigation control further comprises an electrolysis source, water, and an oil layer on the water for displacing oxygen based on hydrogen fueled electrolysis. ### Claim 8 (depends on 1) The device of claim 1 further comprising a magnetic element disposed proximate to the capillary structure and configured for generating a magnetic field around the capillary structure, the print medium responsive to the magnetic field for augmenting a flow rate. ### Claim 9 (depends on 8) The device of claim 8 wherein the magnetic element further comprises a magnetohydrodynamic (MHD) linear motor. ### Claim 10 (depends on 1) The device of claim 1 further comprising a baffle suspended in the reservoir above an outflow to the capillary structure, the baffle extending over an area above the outflow for dispersing semisolid particles of the molten feedstock for avoiding an accumulation and clogging of the outflow by the particles. ### Claim 11 A molten metal print deposition device, comprising: a reservoir in fluid communication with a deposition head for controlled deposition of a print medium defined by molten feedstock; a capillary structure adapted to maintain the molten feedstock from the melt reservoir in a fluidic state for directing and depositing the feedstock onto a substrate; a thermal source for maintaining the molten feedstock at a temperature above the liquidus of the print medium during deposition a feedstock transport configured for transporting feedstock into the reservoir; and a seal at an entry of the feedstock into the reservoir, the seal forming a pressure vessel defined by the reservoir, the seal and the capillary structure, a pressure in the pressure vessel moderating a flow rate of the molten feedstock via the capillary structure. ### Claim 12 (depends on 11) The device of claim 11 further comprising: a wire feed for transporting a feedstock wire into the reservoir, the seal surrounding the wire; and a sealing liquid between a surface of the feedstock wire and the seal. ### Claim 13 (depends on 1) The device of claim 1 wherein the plurality of elongated strands define a brush having a deposition end distal from the reservoir and a bound end proximate to the reservoir, the print medium received by the brush at the proximate end, further comprising a metering protrusion disposed for insertion between the strands at the proximate end, the metering protrusion compressing the strands for limiting capillary flow along the strands. ### Claim 14 (depends on 11) The device of claim 11 further comprising: an extruder coupled to the reservoir for introducing feedstock in a non-molten state into the reservoir; and a sealant liquid disposed around the seal, the sealant liquid having a solidus temperature below a melting point of the feedstock.