Method and apparatus for metal solid freeform fabrication utilizing partially solidified metal slurry

An apparatus for producing a component at least in part from partially solidified material slurry comprising:

• a source of partially solidified material slurry;
• a nozzle having an orifice with a minimum dimension of at least 250 microns attached to said source through which said slurry is dispensed;
• a substrate;
• a solid phase element mounted to said substrate upon which dispensed slurry is at least partially deposited, said element being movable relative to said nozzle;
• and
• a controller for controlling relative movement between said nozzle and said element.

A method for joining a plurality of elements utilizing partially solidified material slurry comprising the steps of:

• providing a source of partially solidified material slurry;
• dispensing said slurry through a nozzle of said source, said nozzle having an orifice with a minimum dimension of at least 250 microns;
• orientating said plurality of elements to form a groove between said plurality of elements;
• and
• depositing said slurry in said groove by coordinating relative movement between said nozzle and said elements in a predetermined manner.

A method for producing a component utilizing partially solidified material slurry comprising the steps of:

• providing a source of partially solidified material slurry;
• dispensing said slurry through a nozzle of said source, said nozzle having an orifice with a minimum dimension of at least 250 microns;
• providing a solid element;
• orientating said solid element relative to said nozzle by coordinating relative movement between said nozzle and said solid element in a predetermined manner;
• and
• depositing said slurry onto said solid element to increase a dimension thereof.