Systems and methods for additive manufacturing magnetic solenoids

A method of forming a magnetically-enabled part via additive manufacturing, the method comprising steps of:

• depositing a first plurality of layers of a first additive manufacturing material on a build plate so as to form a base region;
• calculating an amount of mass consumed as the first plurality of layers is being deposited;
• melting or sintering the first plurality of layers;
• depositing a second plurality of layers of the first additive manufacturing material and a second additive manufacturing material on the first plurality of layers so as to form a transition region;
• triggering the step of depositing the second plurality of layers according to the calculated predetermined amount of mass consumed;
• melting or sintering the second plurality of layers;
• depositing a third plurality of layers of the second additive manufacturing material on the second plurality of layers so as to form a terminal region,
• the additive manufacturing material of at least some of the layers being magnetically permeable;
• and
• melting or sintering the third plurality of layers,
• such that the transition region includes at least some of the magnetically permeable additive manufacturing material.