Apparatus and method for making uniformly sized and shaped spheres

An apparatus for forming uniformly sized and shaped spheres comprising:

• a crucible for containing a supply of a low viscosity liquid material,
• a stimulation means for applying a minute periodic disturbance to the low viscosity liquid material in the crucible,
• a pressure regulator means for applying a pressure to the low viscosity liquid material to force the low viscosity liquid material through at least one orifice in the crucible as a steady laminar stream, the stream breaking up into a plurality substantially uniformly sized spheres upon existing the orifice,
• a charging means for applying a charge to the stream of low viscosity liquid material as the stream exits the orifice and breaks up into the spheres,
• a deflection means for deflecting the charged spheres as the charged spheres pass through an electric field generated by the deflection means, and
• an enclosed controlled temperature solidification environment which defines a first or gaseous environment and which contains at least one heat transfer medium, the enclosed controlled temperature solidification receiving the stream of low viscosity liquid material and the spheres, the heat transfer medium in the first or gaseous environment absorbs the heat of fusion, cooling and substantially solidifying the spheres,
• the enclosed controlled temperature solidification environment further including a second or liquid environment which absorbs the specific heat of the spheres and cushions the spheres before the spheres contact a bottom of the enclosed controlled temperature solidification environment.