Research on accurate droplet generation for micro-droplet deposition manufacture

Micro-droplet deposition manufacture is a novel direct metal rapid prototyping for building the miniaturized parts. In this paper, the relationship between the droplet diameter and the operating parameters is investigated to obtain the optimal condition for the accurate droplet generation. The droplet generator is designed to adjust the parameters such as the infinitesimal disturbance and the jet velocity. Experiments with the different materials have been conducted to study the feasibility of the accurate droplet generation for the manufacturing. Spherical and uniform water micro-droplets within 2.4% variation are generated using an orifice diameter of 150 μm, and tin–lead alloy droplets are produced with an orifice diameter of 100 μm in the argon environment. The results show that the generator can produce accurate micro-droplets which meet the requirements of fabricating the miniaturized parts.