Abstract: Provided are systems and methods for regulation of mass flow and monitoring of volumetric flow, for regulation of volumetric flow and monitoring of mass flow, and for regulation of both mass and volumetric flow of gas to a plasma torch for wire-plasma arc additive manufacturing processes, and methods for manufacturing metal objects by additive manufacturing using one or more of the systems.

Abstract: Additive manufacturing systems with standoff distance monitoring and control, which can be responsive, dynamic, and in real-time. These technologies can use a standoff distance measurement system to real-time monitor, read, or interrogate a workpiece or a substrate on which the workpiece is positioned, as the workpiece is moved past a directed energy source, or vice versa. These technologies can use a feedback controller to responsively and dynamically control the standoff distance in real-time based on data from the standoff distance measurement system.