Uniform molten metal droplet stream from jet break-up provides potential technology for metal parts rapid prototype manufacturing. In this study an experimental device capable of producing uniform metal droplet stream has been developed. Monosize spherical powders of 180?m in diameter can be obtained after cooling and solidification. Then the droplets were electrostatically charged and deflected during flight to deposit onto a revolving substrate to form a 3D metal part. © (2012) Trans Tech Publications, Switzerland.