Magnetohydrodynamic (MHD) metal jetting is a novel additive manufacturing method where parts can be manufactured by precisely depositing molten metal droplets. This thesis work explores the possibility of using such a method to print engineered lattice structures without the aid of any support material. It was determined through experiments that by carefully controlling the droplet jetting frequency, the droplet step-over distance, and the stand-off distance between the print head and the substrate, pillars with varying angles to the substrate could be printed. Also presented is the parameter study which maps droplets jetting frequency, and droplet step-over distance with the angle of the printed strut. The experiments discussed here were conducted using 4043 Aluminum and the approach can be considered as a generalization that could be extended to any metal that can be jetted using the Magnetohydrodynamic jetting process.
Industrial and Systems Engineering (MS)
Department, Program, or Center
Industrial and Systems Engineering (KGCOE)
Jayabal, Dinesh Krishna Kumar, "3D Printing Support-less Engineered Lattice Structures via Jetting of Molten Aluminum Droplets" (2019). Thesis. Rochester Institute of Technology. Accessed from
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