Study of orifice fabrication technologies for the liquid droplet radiator

Eleven orifice fabrication technologies potentially applicable for a liquid droplet radiator are discussed. The evaluation is focused on technologies capable of yielding 25-150 microns diameter orifices with trajectory accuracies below 5 milliradians, ultimately in arrays of up to 4000 orifices. An initial analytical screening considering factors such as trajectory accuracy, manufacturability, and hydrodynamics of orifice flow is presented. Based on this screening, four technologies were selected for experimental evaluation. A jet straightness system used to test 50-orifice arrays made by electro-discharge machining (EDM), Fotoceram, and mechanical drilling is discussed. Measurements on orifice diameter control and jet trajectory accuracy are presented and discussed. Trajectory standard deviations are in the 4.6-10.0 milliradian range. Electroforming and EDM appear to have the greatest potential for Liquid Droplet Radiator applications. The direction of a future development effort is discussed.