Crucible and spindle for a variable size drop deposition system

Abstract

An apparatus for forming three-dimensional objects includes a crucible ( 1 ) for holding a molten material; a conically-shaped orifice ( 1 a ) having a fixed outlet diameter (d o ) at the bottom of the crucible through which a jet ( 50 ) of the molten material flows towards the substrate; and an oscillating mechanical member ( 5 ) for breaking the flow of molten material into the molten material drops ( 60 ). The oscillating mechanical member further includes a conically-shaped head ( 5 a ) for cooperating with the orifice ( 1 a ) and for varying the effective size of the orifice. The conically-shaped head includes a slanted radial portion ( 5 c ) and a tip portion ( 5 b ) extending through the orifice. The effective diameter (d eff ) of the jet is defined by the relationship d eff =[d 0 2 −(d 0 −δ tan θ) 2 ] 1/2 , wherein δ represents the amount of the tip portion extending through the orifice, and θ represents a slant angle corresponding to the slanted radial portion of the conically-shaped head.

1 . (canceled)  
   
   
       2 . (canceled)  
   
   
       3 . (canceled)  
   
   
       4 . An apparatus for producing molten material drops to be used in a system for manufacturing a three-dimensional object by deposition of molten material drops on a substrate, where said apparatus comprises: 
 (i) a crucible for holding a reservoir of molten material;    (ii) a conically-shaped orifice having a fixed outlet diameter ranging from 10 micrometers to 1 millimeter disposed in the bottom of said crucible through which a jet of said molten material flows towards said substrate; and    (iii) an oscillating mechanical member having a conically-shaped head for cooperating with said orifice, the conically-shaped head comprising a slanted radial portion and a tip portion which may be extended through the orifice, wherein the slanted radial portion defines a slant angle θ with the radial axis of the oscillating member, and said slant angle ranges from 5 to 30 degrees, and wherein the relative configurations of the conically shaped orifice and the oscillating mechanical member are sufficient, upon oscillation of the member having the conically shaped head, to produce molten material drops.