Scalable additive manufacturing systems for handling complex feed materials

A system for additive manufacturing, comprising:

• a magazine including a feed material, the feed material including:
• a sheath formed of a material configured to transition from a solid phase to a gaseous phase when exposed to energy, the sheath defining a channel therethrough, and a particulate material disposed within the channel;
• an end effector configured to receive the feed material and direct the feed material towards a substrate;
• a feed assembly operably coupled to the magazine and the end effector, the feed assembly configured to communicate the feed material from the magazine to the end effector;
• and
• an energy source configured to direct energy to the feed material, the energy configured to cause:
• the particulate material to melt to form a melt pool on the substrate, and
• the sheath to transition from the solid phase to the gaseous phase such that the sheath is inhibited from entering the melt pool.

A system for additive manufacturing, comprising:

• a feed assembly, the feed assembly including:
• a drive assembly configured to receive a feed material and displace the feed material along a length thereof;
• and
• an annealer configured to heat a portion of the feed material to an annealing temperature to increase workability of the feed material;
• an end effector, the end effector including:
• a chuck configured to accept the feed material;
• an energy source configured to melt at least a portion of the feed material to form a melted portion of the feed material;
• and
• a nozzle operably coupled to the chuck, the nozzle configured to deposit the melted portion of the feed material onto a substrate to form a melt pool;
• and
• an ultrasonic oscillating source operably coupled to the end effector, the ultrasonic oscillating source configured to vibrate a tip of feed material to induce a separation of the melted portion from the tip of the feed material.

A system for additive manufacturing, comprising:

• a feed assembly, the feed assembly including:
• a drive assembly configured to receive a feed material and displace the feed material along a length thereof;
• and
• an annealer configured to heat a portion of the feed material to an annealing temperature to increase workability of the feed material;
• an end effector, the end effector including:
• a chuck configured to accept the feed material;
• an energy source configured to melt at least a portion of the feed material to form a melted portion of the feed material;
• and
• a nozzle operably coupled to the chuck, the nozzle configured to deposit the melted portion of the feed material onto a substrate to form a melt pool;
• and
• a controller communicably coupled to at least one of the feed assembly or the end effector, the controller configured use an input shaping control algorithm configured to reduce vibrations in the at least one of the feed assembly or the end effector.

A system for additive manufacturing, comprising:

• a feed assembly, the feed assembly including:
• a drive assembly configured to receive a feed material and displace the feed material along a length thereof;
• and
• an annealer configured to heat a portion of the feed material to an annealing temperature to increase workability of the feed material;
• an end effector, the end effector including:
• a chuck configured to accept the feed material;
• an energy source configured to melt at least a portion of the feed material to form a melted portion of the feed material;
• and
• a nozzle operably coupled to the chuck, the nozzle configured to deposit the melted portion of the feed material onto a substrate to form a melt pool;
• and
• a bender disposed between the drive assembly and the end effector, the bender configured to selectively bend the feed material from a first direction of travel to a second direction of travel.

A system for additive manufacturing, comprising:

• a feed assembly, the feed assembly including:
• a drive assembly configured to receive a feed material and displace the feed material along a length thereof;
• and
• an annealer configured to heat a portion of the feed material to an annealing temperature to increase workability of the feed material;
• an end effector, the end effector including:
• a chuck configured to accept the feed material;
• an energy source configured to melt at least a portion of the feed material to form a melted portion of the feed material;
• and
• a nozzle operably coupled to the chuck, the nozzle configured to deposit the melted portion of the feed material onto a substrate to form a melt pool;
• and
• a straightener disposed between the drive assembly and the end effector, the straightener configured to selectively straighten the feed material.