Method and apparatus for creating a free-form three-dimensional article using a layer-by-layer deposition of molten metal and using a stress-reducing annealing process on the deposited metal

A method for the accurate formation of a free-form three-dimensional article without the use of a mold of the three-dimensional article, the method comprising:

• providing a supply of substantially uniform size droplets of a desired molten or semimolten metal material, each droplet having the same positive or negative charge,
• aligning each droplet in the supply of droplets into a substantially single file stream, the droplets being aligned by allowing the droplets to pass through at least one alignment means, the alignment means having the same charge as the droplets wherein the alignment means repels each droplet toward an axis extending through the alignment means,
• depositing each of the aligned droplets in a pattern defining a shape of the three-dimensional article onto a target, the droplets being deposited onto the target along the axis extending longitudinally through the alignment means wherein the axis is substantially perpendicular to a top surface of the target, the deposited droplets forming at least one layer of the three-dimensional article, wherein the three-dimensional article comprises a plurality of the layers of the deposited droplets, and
• reducing stress in the deposited droplets by annealing the deposited droplets as the deposited droplets form the newly formed layer of the three-dimensional article, by using a source of laser energy to reduce the stress in the deposited droplets.