Method and system for additive manufacturing of electrical devices

A method of forming an electrical device, the method comprising:

• applying, by a first system head, one or more layers of a first solid starting material, at least one layer of the one or more layers of the first solid starting material being applied onto a central core of the electrical device;
• fusing the applied one or more layers of the first solid starting material to form an insulator layer;
• determining that an insulating capacity of the applied one or more layers of the first solid starting material does not satisfy a predetermined threshold;
• continuing the applying the one or more layers of the first solid starting material at least until the insulating capacity satisfies the predetermined threshold;
• applying, by a second system head, one or more layers of a second solid starting material onto at least a portion of the insulator layer;
• fusing the applied one or more layers of the second solid starting material to form an electrical conductor layer;
• repeating the applying the at least one layer of the first solid starting material, the fusing the applied one or more layers of the first solid starting material, the determining whether an insulating capacity of the applied one or more layers of the first solid starting material satisfies a predetermined threshold, continuing the applying the one or more layers of the first solid starting material at least until the insulating capacity satisfies the predetermined threshold, the applying the one or more layers of the second solid starting material, and the fusing the applied one or more layers of the second solid starting material to form a plurality of insulator layers and a plurality of electrical conductor layers;
• applying, by the first system head, one or more layers of the first solid starting material to form an outer insulator layer about an outermost layer of the plurality of electrical conductor layers;
• and
• wherein at least one of the one or more layers of the first solid starting material comprises a lattice structure having a plurality of hollow regions encasing at least one of an electrically insulating gas or a vacuum.