US 11,890,674 B2
Metal drop ejecting three-dimensional (3D) object printer and method of operation for forming support structures in 3D metal objects
Christopher T. Chungbin, Webster, NY (US); PriyaankaDevi Guggilapu, Webster, NY (US); Daniel R. Cormier, Pittsford, NY (US); David G. Tilley, Williamson, NY (US); David A. Mantell, Rochester, NY (US); and Michael F. Dapiran, Webster, NY (US)
Assigned to Xerox Corporation, Norwalk, CT (US)
Filed by Xerox Corporation, Norwalk, CT (US); and Palo Alto Research Center Incorporated, Palo Alto, CA (US)
Filed on Mar. 1, 2022, as Appl. No. 17/652,988.
Prior Publication US 2023/0278103 A1, Sep. 7, 2023
Int. Cl. B33Y 30/00 (2015.01); B33Y 50/02 (2015.01); B22F 10/85 (2021.01); B22D 23/00 (2006.01); B22F 10/22 (2021.01); B33Y 10/00 (2015.01); B22F 12/50 (2021.01)
CPC B22F 10/22 (2021.01) [B22D 23/003 (2013.01); B22F 10/85 (2021.01); B22F 12/50 (2021.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 50/02 (2014.12)] 8 Claims
OG exemplary drawing
 
1. A metal drop ejecting apparatus comprising:
an ejector head configured to eject melted metal drops through a nozzle;
a planar member positioned to receive melted metal drops ejected from the ejector head; and
a controller operatively connected to the ejector head, the controller being configured to:
move the ejector head over the planar member and operate the ejector head at a first ejection frequency to form a first line of spatially separated pillars on the planar member with metal drops ejected from the ejector head, the pillars in the spatially separated pillars are separated from one another by a predetermined distance; and
move the ejector head over the first line of spatially separated pillars and operate the ejector head at a second ejection frequency and a first drop spacing to eject melted metal drops that form a continuous metal line over the first line of spatially separated pillars in a single pass, the second ejection frequency being different than the first ejection frequency.