Scalable additive manufacturing systems for handling complex feed materials

Abstract

A scalable additive manufacturing system for handling complex feed materials which includes a feed assembly including a drive assembly configured to receive a feed material and selectively displace the feed material along a length thereof, an annealer configured to selectively heat a portion of the feed material to an annealing temperature to increase workability of the wire, and an end effector. The end effector includes a chuck configured to accept the feed material, a directed energy source configured to selectively melt at least a portion of the feed material, and a nozzle operably coupled to the chuck, the nozzle configured to selectively deposit the melted portion of the feed material onto a substrate to form a melt pool. The feed material may be a core-wire that can include a core formed of a first material, and a sheath formed from a second material different from the first material.