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 processing head assembly is provided for use with a movable tool holder of a machine tool. The processing head assembly includes an upper processing head coupled to the movable tool holder and having a body defining a socket, and a feed powder/propellant port coupled to the body and operably coupled to a feed powder/propellant supply. The processing head assembly further includes a lower processing head having a base configured to be releasably coupled to the socket, and a nozzle coupled to the base and defining a feed powder/propellant interface configured to detachably couple to the feed powder/propellant port and a nozzle exit orifice.

Abstract: Methods and apparatus for performing additive manufacturing processes using a machine tool may include controlling an orientation of a processing head to control the tangential angle of a fabrication energy beam, a feed powder nozzle, or both. The orientation of a non-circular energy beam may be control to more evenly distribute the energy beam across a width of a tool path. Additionally or alternatively, the orientation of the feed powder nozzle may be controlled to project toward a powder target that is spaced from a beam target. The powder target may be directed to a trailing edge of a beam spot formed by the energy beam to increase the amount of powder incorporated into a melt pool formed by the energy beam. Alternatively, the powder target may be directed to a leading edge of the beam spot to provide a self-correcting feature to address thickness errors formed in previous layers of added material.