Apparatus for creating a free-form three-dimensional article using a layer-by-layer deposition of a molten metal and deposition of a powdered metal as a support material

An apparatus for the accurate formation of a free-form three-dimensional article without the need for the use of a mold of the three-dimensional article, the apparatus comprising:

• at least one means for supplying substantially uniform size droplets of a desired metal material, each droplet having a positive or negative charge;
• and
• a means for aligning the supply of droplets into a substantially narrow stream, the aligned droplets being deposited in a predetermined pattern at a predetermined rate onto a target or a newly formed layer of the three-dimensional article to form the three-dimensional article wherein the alignment means repels the droplets toward an axis extending through the alignment means until each droplet is deposited on the target or the newly formed layer of the three-dimensional article;
• wherein the supply means provides a first quantity of droplets at a first distance from the target, each droplet of the first quantity of droplets bonding to at least the target or one earlier deposited droplet;
• and wherein the supply means provides a second quantity of droplets at a second distance from the target, each droplet of the second quantity of droplets having a different temperature than the temperature of the first quantity of droplets;
• wherein, as the second quantity of droplets contacts the target or previously deposited droplets, the second quantity of droplets does not bond to the earlier deposited droplets or to other droplets of the second quantity of droplets.