| Abstract Scope |
We present a novel drop-on-demand additive manufacturing (AM) technology that utilizes metal sheets as the donor feedstock for production at the microscale. Our approach utilizes nanosecond-pulsed laser energy to precisely eject metallic droplets on demand, enabling the layer-by-layer consolidation of parts. By replacing powder feedstock with continuously fed metallic sheets, this technology reduces printing time and materials costs. Leveraging a lab-scale working prototype, we explore the various ejection regimes and investigate the limits of attainable print resolution. Additionally, we investigate the influence of crucial process parameters, including laser fluence, pulse duration, and pulse frequency, on droplet properties such as shape and size. Moreover, our research delves into the impact of droplet-substrate interaction by analyzing how droplet properties vary at different donor-acceptor distances. This innovative technology opens up new possibilities for microscale manufacturing with improved efficiency and cost-effectiveness. |