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Metal droplet-based 3D printing provides unique advantages for fabricating micro complex parts. Especially, assisted by soluble support, structures with high-quality inner surfaces can be directly printed without post-processing, which is very promising for the fabrication of waveguides and antenna horns. Here, a spatially distributed equidistant helical deposition strategy with only one-step positioning was proposed to improve the inner surface quality of the parts, and a five-axis motion stage was designed for matching its motion planning. The influence mechanisms of key process parameters on the forming quality were investigated. The droplet positioning errors, the aggregation behaviour, and the hole-defects formation on sloping surfaces were analyzed. As a proof-of-concept, a horn-structured tube was directly printed via the proposed printing method, which possessed both high-quality cavity surfaces and high density. This work paves the route towards the efficient additive manufacturing of metal tubes with high-quality inner surfaces.

Metal droplet-based 3D printing provides unique advantages for fabricating micro complex parts. Especially, assisted by soluble support, structures with high-quality inner surfaces can be directly printed without post-processing, which is very promising for the fabrication of waveguides and antenna horns. Here, a spatially distributed equidistant helical deposition strategy with only one-step positioning was proposed to improve the inner surface quality of the parts, and a five-axis motion stage was designed for matching its motion planning. The influence mechanisms of key process parameters on the forming quality were investigated. The droplet positioning errors, the aggregation behaviour, and the hole-defects formation on sloping surfaces were analyzed. As a proof-of-concept, a horn-structured tube was directly printed via the proposed printing method, which possessed both high-quality cavity surfaces and high density. This work paves the route towards the efficient additive manufacturing of metal tubes with high-quality inner surfaces. [ABSTRACT FROM AUTHOR]