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A method and apparatus for the accurate formation of a three-dimensional article comprises providing a first quantity and a second quantity of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. Each quantity of droplets is focused or ali

A method and apparatus for the accurate formation of a three-dimensional article comprises providing a first quantity and a second quantity of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. Each quantity of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment means which repels each droplet toward an axis extending through the alignment means. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without a mold of the shape of the three-dimensional article. The droplets of the first quantity and the second quantity are supplied at different distances, whereby the droplets of the first quantity bond to each other and the droplets of the second quantity do not bond to each other or to the first quantity of droplets.

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[ We claim:] [1.] A method for forming a free-form article without using a mold to define a shape of the article, the method comprising:providing an object geometry of the article, the object geometry comprising a plurality of two-dimensional cross-sectional layers parallel to each other, each cross

[ We claim:] [1.] A method for forming a free-form article without using a mold to define a shape of the article, the method comprising:providing an object geometry of the article, the object geometry comprising a plurality of two-dimensional cross-sectional layers parallel to each other, each cross-sectional layer being located at predetermined points relative to the article along an axis perpendicular to the cross-sectional layers,providing a first quantity and a second quantity of droplets of a metal material, the droplets having substantially the same diameter and the same positive or negative charge;said cross-sectional layer of the object geometry defined by a first set and a second set of predetermined patterns in which the droplets are deposited, the first set of patterns comprising the cross-sectional layers of the article and the second set of patterns comprising a complement of the cross-sectional layers of the article, the second set of patterns extending to support overhanging portions of subsequent layers of the article;aligning the first quantity and the second quantity of the droplets into a stream; the droplets being aligned by allowing the droplets to pass adjacent or through at least one alignment means having the same charge as the droplets wherein the alignment means repels the droplets toward an axis extending longitudinally through the alignment means;depositing the first quantity of the droplets in the first set of patterns in a substantially molten or semi-molten state onto a target or a newly formed layer of the article whereby the droplets of the first quantity of the droplets bond to the target or to at least one earlier deposited droplet of the first quantity of droplets;depositing the second quantity of the droplets in the second set of patterns in a fully-solid state onto the target or the deposited first quantity of droplets forming the article, the second quantity of droplets forming a removable support structure for receiving the first quantity of droplets in subsequent layers which define the overhanging portions of the article;whereby the droplets of the second quantity of the droplets do not bond to the first quantity of the droplets or to the droplets of the second quantity of the droplets; and,removing the second quantity of droplets, which formed the removable support structure, from the target and the article after depositing all the layers of droplets.