Sustainable metal droplet formation via open-source, cost-effective, and modifiable droplet generator

In this study, a metal droplet generator developed with an open-source concept is presented. The continuous droplet generation process was achieved without inert gas assistance. Owing to this desktop device, which is proposed as an alternative to high-cost metal printing devices, users can achieve stable droplets continuously at low costs. Taking into account the pressure balance inside the melting region, the necessary amount of a metal wire feed was first revealed. The droplets generated which are in good agreement with the theoretical calculations were then ejected via mechanically restricted vibrational impacts. The reproducibility of the system was also tested. The droplet formation stages were classified, and the stable parameter groups were revealed in accordance with the measurements. Moreover, the wire type material feeding issue in metal droplet generators, which were insufficiently studied so far, has also been examined. A dynamic feeder mechanism was introduced in detail. In conclusion, Ball Grid Array deposition and functional circuit printing have been successfully achieved. This study on a continuous metal droplet formation is also important for future studies because the structure of the device is easily accessible and modifiable.