Abstract: A machine for additive manufacturing positions a film having additive material relative to a substrate. The additive material is melted onto the substrate or previously formed layers of a workpiece using a laser. The substrate/workpiece and/or the film can be positioned in multiple axes so that complex shapes can be formed without extraneous supporting structures. The film-based delivery of the additive material allows deposition in orientations other than horizontal as is required for powder-only additive manufacturing and also avoids the inconvenience of collecting and recycling unused loose powdered metal.

Abstract: A system for manufacturing a build object includes an additive manufacturing tool configured to utilize a powdered reactive material to construct the build object. The powdered reactive material includes a plurality of powder beads, wherein each powder bead has a bead diameter that is substantially similar to an ideal bead diameter. The system further includes apparatus configured to selectively shield the build object during additive manufacturing of the build object, by the additive manufacturing tool, using an inert gas. The ideal bead diameter is configured to be a bead diameter at which ignition of the powdered reactive material is inhibited, upon oxidation of the powdered reactive material.

Abstract: A machine for additive manufacturing positions a film having additive material relative to a substrate. The additive material is melted onto the substrate or previously formed layers of a workpiece using a laser. The substrate/workpiece and/or the film can be positioned in multiple axes so that complex shapes can be formed without extraneous supporting structures. The film-based delivery of the additive material allows deposition in orientations other than horizontal as is required for powder-only additive manufacturing and also avoids the inconvenience of collecting and recycling unused loose powdered metal.