Molten metal jetting for additive manufacturing

1. A method of molten metal jetting for additive manufacturing, comprising:

feeding a wire of solid metal material along a material feed path;

melting the solid metal material to molten metal in a melt reservoir;

pressurizing the melt reservoir to a predetermined pressure insufficient to eject droplets;

generating a pressure oscillation in the molten metal in the melt reservoir to force at least one of jetting of the molten metal through a nozzle and formation of molten metal droplets by surface tension at the nozzle;

driving the nozzle to relatively move with respect to a build plate in at least three degrees of freedom;

forming successive layers of solidified metal by accumulation of the molten metal droplets impacting a previously deposited layer of solidified metal and cooling thereon; and

driving at least one of the nozzle and the build plate to move such that a normalizing grinding wheel connected to the nozzle traverses each successive layer to automatically level each successive layer.

2. The method according to claim 1 , wherein the normalizing grinding wheel is driven to traverse with its rotating axis entirely within a plane parallel to a plane in which a layer is formed.

3. The method according to claim 1 , wherein the normalizing grinding wheel removes sufficient material to shave both peaks and valleys in an irregular surface.

4. The method according to claim 3 , wherein the normalizing grinding wheel removes 10-80% of the deposited solidified metal height.

5. The method according to claim 1 , wherein the grinding wheel is traversed over an area of no more than 125% of the area of the previously deposited solidified metal layer.

6. The method according to claim 1 , wherein one of an inert gas supply and an inert gas generator supplies an inert gas to shield the molten metal from oxidation.

7. The method according to claim 6 , wherein the supply of inert gas is shared among at least two of the following:

a. an inert gas feed to maintain an oxidation-free environment in the melt reservoir,

b. an inert gas feed to maintain an oxidation-free environment in a print chamber, and

c. an inert gas feed to maintain an oxidation shield extending between the nozzle and the build plate and about the molten droplets as they are jetted.

8. A method of molten metal jetting for additive manufacturing, comprising:

feeding a wire of solid metal material along a material feed path;

melting the solid metal material to molten metal in a melt reservoir;

pressurizing the molten metal in the melt reservoir to a predetermined pressure insufficient to eject droplets;

supplying inert gas to shield the molten metal from oxidation from one of an inert gas supply and an inert gas generator;

generating a pressure oscillation in the molten metal in the melt reservoir to force at least one of jetting of molten metal through a nozzle of a print head and formation of molten metal droplets by surface tension at the nozzle;

driving the nozzle to relatively move with respect to a build plate in at least three degrees of freedom;

forming, in a chamber, a part with successive layers of solidified metal by accumulation of the molten metal droplets impacting a previously deposited layer of solidified metal and cooling thereon;

inspecting the successive layers of solidified metal with an optical inspection system; and

adjusting the pressure oscillation in the molten metal based on the inspecting with the optical inspection system.

9. The method according to claim 8 , further comprising:

loading the melt reservoir by introducing an initial charge of unmelted material to the melt reservoir;

feeding inert gas into the print head;

introducing a cleaning material into the print head;

heating the print head to activate the cleaning material; and

removing, through the nozzle, metal and oxidized metal from the print head.

10. The method according to claim 9 , wherein removing metal and oxidized metal from the print head includes feeding cleaning material, metal, and inert gas into the nozzle.

11. The method according to claim 8 , further comprising:

locking a sealed door of the chamber; and

in response to locking the door and before removing the part from the chamber, purging the chamber by at least one of removing oxygen from the chamber and flowing inert gas into the chamber.

12. The method according to claim 8 , further comprising:

locking a sealed door of the chamber; and

in response to locking the door and before removing the part from the chamber, purging the melt reservoir by at least one of removing oxygen from the melt reservoir and flowing inert gas into the melt reservoir.

13. The method according to claim 8 , further comprising:

locking a sealed door of the chamber; and

in response to locking the door and before forming the part, purging the chamber by at least one of removing oxygen from the chamber and flowing inert gas into the chamber.

14. The method according to claim 8 , further comprising:

locking a sealed door of the chamber; and

in response to locking the door and before forming the part, purging the melt reservoir by at least one of removing oxygen from the melt reservoir and flowing inert gas into the melt reservoir.

15. The method according to claim 8 , further comprising:

locking a sealed door of the chamber; and

in response to locking the door and before forming the part, purging the melt reservoir by flowing anoxic gas through the melt reservoir in a gaseous volume in excess of a melt reservoir volume.

16. The method according to claim 1 , further comprising:

inspecting the successive layers of solidified metal with an optical inspection system; and

adjusting the driving of the at least one of the nozzle and the build plate based on the inspecting with the optical inspection system.