Method and system for additive manufacturing using high energy source and hot-wire

An additive manufacturing system, comprising:

• a high energy device which irradiates a surface of a work piece with a high energy discharge to create a molten puddle on a surface of said work piece;
• and
• a power supply which supplies a heating signal to a consumable wire where said heating signal comprises a plurality of current pulses and where each of said current pulses creates a molten droplet on a distal end of said consumable which is deposited into said puddle;
• wherein each of said current pulses reaches a peak current level after said distal end of said consumable contacts said puddle,
• wherein said heating signal has no current in between said plurality of said current pulses;
• wherein said distal end of said consumable is not in contact with said puddle between subsequent peak current levels of said current pulses;
• wherein said power supply controls said heating current such that no arc is created between said wire and said work piece during said current pulses;
• and
• wherein said consumable has each of a sheath portion and a core portion, where said sheath portion has a melting temperature less than a melting temperature of said core portion.