METAL DROP EJECTING THREE-DIMENSIONAL (3D) OBJECT PRINTER AND METHOD OF OPERATION FOR BUILDING SUPPORT STRUCTURES
A three-dimensional (3D) metal object manufacturing apparatus is equipped with a silicate slurry application system to build support structure layers with fused particulate suspended in the silicate slurry or to apply a layer of the silicate slurry to a metal support structure prior to manufacture of a metal object feature that is supported by either type of support structure. The fused particulate of a silicate support structure or a layer applied to a surface of a metal support structure forms a glassy, brittle layer on which the metal object feature is formed. This glassy, brittle structure is removed relatively easily from the object after the object is manufactured.
1 - 10 . (canceled)
11 . A method of operating a metal drop ejecting apparatus comprising:
operating an extruder to apply a layer of a silicate slurry to a surface; and
operating an ejector head to eject melted metal drops onto the layer of the silicate slurry.
12 . The method of claim 11 further comprising:
operating an articulated arm to move the extruder in a three-dimensional (3D) space over a planar member; and
operating the extruder to apply the layer of the silicate slurry to the surface while the extruder is being moved in the 3D space.
13 . The method of claim 12 further comprising:
operating an actuator to expel the silicate slurry from the extruder.
14 . The method of claim 13 wherein the operation of the actuator drives a plunger to expel the silicate slurry.
15 . The method of claim 13 wherein the operation of the actuator drives a lead screw to expel the silicate slurry.
16 . The method of claim 12 further comprising:
operating the ejector head to eject melted metal drops to form layers of a support structure;
operating the articulated arm and the extruder to apply the layer of the silicate slurry to a surface of the support structure formed with the melted metal drops; and
operating the ejector head to eject melted metal drops onto the layer of the silicate slurry on the surface of the support structure.
17 . The method of claim 16 further comprising:
delaying a predetermined period of time before operating the ejector head to eject melted metal drops onto the layer of the silicate slurry.
18 . The method of claim 12 further comprising:
operating the articulated arm and the extruder to form layers of a support structure with the silicate slurry; and
operating the ejector head to eject melted metal drops on the support structure formed with the silicate slurry.
19 . The method of claim 18 further comprising:
delaying a predetermined period of time before operating the ejector head to eject melted metal drops onto the support structure formed with the layers of the silicate slurry.
20 . The method of claim 12 further comprising:
operating the extruder to form a layer of the silicate slurry on the planar member.