Exploration of laser-induced drop transfer modes from wire for AM

Laser-induced ablation of drops from a metal wire enables the sequential deposition of voxels, for additive manufacturing. Striving for the goal of controlled, reproducible drop transfer, for this new technique, further trends and phenomena have been studied. Different modes of drop growth along with necking have been observed. Rather reproducible was a growing pending drop underneath the wire tip until separation for a certain size. In contrast, initial transients from the laser-induced recoil pressure can lead to a quick separation of a smaller drop. Initiation of a swinging cycle can also cause drop ablation after one cycle. For too fast wire feeding, the wire underpins the melt for a while in a spoon-like manner. Apart from the drop size, the different modes affect the scatter of the flight trajectory and landing position, as important optimization criteria, for controlled 3D-printing.