Spray-Formed Structural Joints for Smooth 3D Printed Surfaces

The patent changes the fundamental deposition parameter from layer-by-layer to continuous spray deposition. The spray forming process uses a continuous stream of material that is atomized and deposited in a controlled manner, eliminating the discrete layer structure that causes stair-stepping. This parameter change allows simultaneous achievement of complex geometry fabrication and smooth surface finish.

The patent replaces the mechanical layer-by-layer deposition system with a spray-based deposition system. Instead of physically building up discrete layers, the system uses aerosolized material particles that are deposited continuously, substituting the mechanical stacking process with a fluid dynamics-based deposition process that inherently produces smoother surfaces.

The patent merges the manufacturing and surface finishing operations into a single integrated process. The spray forming technique simultaneously creates the part geometry and produces the desired surface finish in one continuous operation, eliminating the need for separate sanding, machining, or other post-processing steps that would otherwise be required.

The patent implements continuous deposition action throughout the manufacturing process. The spray forming process maintains continuous material flow and deposition, allowing the part to be built and finished in an uninterrupted sequence, thereby eliminating idle time and additional processing steps associated with conventional layer-by-layer methods.