Systems and methods for high performance metal droplet ejection via meniscus control enabled by multi-part ejection nozzle

WO2026019661A4 Publication Date: 2026-03-26LAWRENCE LIVERMORE NAT SECURITY LLC
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Patent Information

Application Number
PCT/US2025/037322
Authority / Receiving Office
WO · WO
Patent Type
Applications
Current Assignee / Owner
Priority Date
2024-07-15
Filing Date
2025-07-11
Publication Date
2026-03-26

AI Technical Summary

Technical Problem

Existing Liquid Metal Jetting (LMJ) systems face challenges in nozzle fabrication, meniscus control, droplet ejection frequency, and nozzle clogging due to undesirable meniscus locations and material incompatibilities, limiting the applicability and scalability of the technology.

Method used

A multi-piece nozzle design comprising a nozzle main body and a wetting plate with distinct wetting characteristics, where the wetting plate is secured to the nozzle main body and features a non-wetting coating to control meniscus location and inhibit wetting, allowing for efficient droplet ejection and reduced clogging.

Benefits of technology

The design improves droplet ejection frequency, reduces nozzle clogging, and enhances the durability and reliability of LMJ systems by decoupling the fabrication of the nozzle main body and wetting plate, enabling the use of optimal materials for each component.

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Abstract

The present disclosure relates to a liquid metal jetting ejection nozzle having a nozzle main body and a wetting plate. The nozzle main body has an enlarged opening at a distal end through which a molten metal feedstock material flows during a liquid metal jetting operation, and is formed from a first material having a first wetting characteristic. The wetting plate has an aperture and is secured to the enlarged opening of the nozzle main body. The wetting plate has a second wetting characteristic of a magnitude less than the first wetting characteristic to at least inhibit wetting. This two piece nozzle construction enables optimum materials and construction / fabrication techniques to be used for both components, thus improving performance, durability and reliability of the ejection nozzle.
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