Enhanced materials and associated manufacturing methods and products

Abstract

Provided herein are a manufacturing method for producing an enhanced material, a manufacturing system for producing an enhanced material, and a product including an enhanced material. The enhanced material can include a base material such as a metal, and an additive material such as a carbon nanomaterial.

Description

[0001] Attorney Docket No. ARC-001-PCT

[0002] ENHANCED MATERIALS AND ASSOCIATED MANUFACTURING METHODS AND PRODUCTS

[0003] RELATED APPLICATIONS

[0004]

[0001] This application claims the benefit of United States Provisional Application Serial Number 63 / 712,659 (Docket No. ARC-001-PR1), titled “ENHANCED MATERIALS AND ASSOCIATED MANUFACTURING METHODS AND PRODUCTS” filed October 28, 2024, the content of which is incorporated by reference in its entirety for all purposes.

[0005] FIELD OF THE INVENTIVE CONCEPTS

[0006]

[0002] The present inventive concepts relate generally to enhanced materials, their methods and systems of manufacture, as well as devices that incorporate the enhanced materials.

[0007] BACKGROUND

[0008]

[0003] Various materials, such as those used in electrical conductors, have properties that limit their use, or are incorporated into products whose performance is limited by their inclusion. There is a need for enhanced materials that avoid these limitations, as well as manufacturing systems and methods to produce these enhanced materials, and products that include these enhanced materials.

[0009] SUMMARY

[0010]

[0004] According to an aspect of the present inventive concepts, a manufacturing method for producing an enhanced material comprises: (a) obtaining source materials comprising at least a base material and an additive material; and (b) processing at least the base material and the additive material to produce the enhanced material or an intermediate enhanced material.

[0011]

[0005] In some embodiments, step (b) is performed using any manufacturing system of the present inventive concepts.

[0012]

[0006] In some embodiments, the enhanced material comprises any enhanced material of the present inventive concepts.

[0013]

[0007] In some embodiments, the enhanced material is integrated into a product, and the product comprises any product of the present inventive concepts. Attomey Docket No. ARC-001 -PCT

[0014]

[0008] In some embodiments, the base material comprises: aluminum; copper; nickel; steel; and / or other metal, and the additive material comprises carbon nanomaterial.

[0015]

[0009] In some embodiments, step (b) comprises a 3D printing process.

[0016]

[0010] In some embodiments, step (b) produces the intermediate enhanced material, and the method further comprises: (c) performing additional processing on the intermediate enhanced material to produce the enhanced material. The additional processing can comprise applying a cover to the intermediate enhanced material to encapsulate at least an additional material.

[0017] [Oi l] According to another aspect of the present inventive concepts, a manufacturing system for producing an enhanced material comprises: processing equipment configured to combine source materials comprising at least a base material and an additive material. The manufacturing system is configured to produce the enhanced material comprising the source materials.

[0018]

[0012] In some embodiments, the manufacturing system is configured to perform any manufacturing method of the present inventive concepts.

[0019]

[0013] In some embodiments, the manufacturing system is configured to produce any enhanced material of the present inventive concepts.

[0020]

[0014] In some embodiments, the processing equipment comprises one or more pieces of equipment selected from the group consisting of: a mixer, such as a ball mill, a high-energy mixer, an ultrasonication device, and / or a bath sonication device; chemical vapor deposition system; a furnace, such as an induction furnace and / or a heat-treatment furnace; a compactor, such as a powder compactor and / or a cold isostatic press; an extruder, such as an extrusion press; a wire drawing machine; a laser powder bed fusion device; an additive printer; a 3D printer; a directed energy deposition device; a diagnostic device; a wire arc additive manufacturing device; an atomizer, such as a powder gas atomizer; an additive printer; and combinations thereof.

[0021]

[0015] In some embodiments, the manufacturing system further comprises a processing unit comprising a processor and a memory storage element coupled to the processor, and the memory storage element stores instructions for the processor to perform an algorithm. The algorithm can comprise an Al algorithm. The algorithm can be configured to adjust a process parameter, an equipment parameter, or both, in a closed-loop arrangement.

[0022]

[0016] According to another aspect of the present inventive concepts, an enhanced material comprises: source materials comprising: a base material; and an additive material. Attorney Docket No. ARC-001 -PCT

[0023]

[0017] In some embodiments, the enhanced material is produced using any manufacturing method of the present inventive concepts.

[0024]

[0018] In some embodiments, the enhanced material is produced using any manufacturing system of the present inventive concepts.

[0025]

[0019] In some embodiments, the enhanced material is integrated into any product of the present inventive concepts.

[0026]

[0020] In some embodiments, the base material comprises a metal. The metal can comprise a metal selected from the group consisting of: aluminum; copper; nickel; steel; and combinations thereof.

[0027]

[0021] In some embodiments, the enhanced material comprises material provided in the form of a fdament.

[0028]

[0022] In some embodiments, the enhanced material comprises material provided in the form of an electrical conductor.

[0029]

[0023] In some embodiments, the additive material comprises a first additive material, and the enhanced material further comprises a second additive material. The second additive material can be constructed and arranged as a cover that can be positioned to prevent exposure of the first additive material to air. The second additive material can comprise a metal, a non-metal, or both.

[0030]

[0024] According to another aspect of the present inventive concepts, a product includes any enhanced material of the present inventive concepts.

[0031]

[0025] In some embodiments, the product comprises a product selected from the group consisting of: power transmission lines; power grids; coils; motors; solenoids; electromagnetic actuators; electric vehicles; any conductor-including product or component; and combinations thereof.

[0032]

[0026] In some embodiments, the product comprises a medical device. The medical device can comprise an implanted device, such as an implanted device selected from the group consisting of: a pacemaker; a defibrillator; a stimulator, such as a pain-treating stimulator and / or a deep brain stimulator; and combinations thereof.

[0033]

[0027] The technology described herein, along with the attributes and attendant advantages thereof, will best be appreciated and understood in view of the following detailed description Attorney Docket No. ARC-001 -PCT taken in conjunction with the accompanying drawings in which representative embodiments are described by way of example.

[0034] INCORPORATION BY REFERENCE

[0035]

[0028] All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference. The content of all publications, patents, and patent applications mentioned in this specification are herein incorporated by reference in their entirety for all purposes.

[0036] BRIEF DESCRIPTION OF THE DRAWINGS

[0037]

[0029] Fig. 1 illustrates a block diagram of an embodiment of an enhanced material, consistent with the present inventive concepts.

[0038]

[0030] Fig. 1A illustrates a block diagram of another embodiment of an enhanced material, consistent with the present inventive concepts.

[0039]

[0031] Fig. 2 illustrates a block diagram of a manufacturing system for producing an enhanced material, consistent with the present inventive concepts.

[0040]

[0032] Fig. 3 illustrates a flow chart of a method for manufacturing an enhanced material, consistent with the present inventive concepts.

[0041]

[0033] Figs. 3A-E illustrate flow charts of various manufacturing steps that can be used to produce an enhanced material, consistent with the present inventive concepts.

[0042]

[0034] Fig. 4 illustrates a block diagram of a product that includes an enhanced material, consistent with the present inventive concepts.

[0043]

[0035] Figs. 5A-C illustrate a manufacturing step for producing an enhanced material, another manufacturing step for producing an enhanced material, and a view of an enhanced material and its associated Raman spectrograph, respectively, consistent with the present inventive concepts.

[0044]

[0036] Fig. 6 illustrates a graph of conductivity versus temperature for an enhanced material and other materials, consistent with the present inventive concepts.

[0045]

[0037] Fig. 7 illustrates a graph of strength / density versus conductivity for an enhanced material and other materials, consistent with the present inventive concepts. Attorney Docket No. ARC-001 -PCT

[0046]

[0038] Fig. 8 illustrates the use of an enhanced material and standard materials for power lines, consistent with the present inventive concepts.

[0047] DETAILED DESCRIPTION OF THE DRAWINGS

[0048]

[0039] Reference will now be made in detail to the present embodiments of the technology, examples of which are illustrated in the accompanying drawings. Similar reference numbers may be used to refer to similar components. However, the description is not intended to limit the present disclosure to particular embodiments, and it should be construed as including various modifications, equivalents, and / or alternatives of the embodiments described herein.

[0049]

[0040] It will be understood that the words "comprising" (and any form of comprising, such as "comprise" and "comprises"), "having" (and any form of having, such as "have" and "has"), "including" (and any form of including, such as "includes" and "include") or "containing" (and any form of containing, such as "contains" and "contain") when used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0050]

[0041] It will be further understood that, although the terms first, second, third, etc. may be used herein to describe various limitations, elements, components, regions, layers and / or sections, these limitations, elements, components, regions, layers and / or sections should not be limited by these terms. These terms are only used to distinguish one limitation, element, component, region, layer or section from another limitation, element, component, region, layer or section. Thus, a first limitation, element, component, region, layer or section discussed below could be termed a second limitation, element, component, region, layer or section without departing from the teachings of the present application.

[0051]

[0042] It will be further understood that when an element (also referred to as a “component” herein) is described as being "on", "attached", "connected" or "coupled" to another element, it can be directly on or above, or connected or coupled to, the other element, or one or more intervening elements can be present. In contrast, when an element is referred to as being "directly on", "directly attached", "directly connected" or "directly coupled" to another element, there are no intervening elements present. Other words used to describe the relationship between Attorney Docket No. ARC-001 -PCT elements should be interpreted in a like fashion (e.g. "between" versus "directly between," "adjacent" versus "directly adjacent," etc.).

[0052]

[0043] As used herein, the terms “operably attached”, “operably connected”, “operatively coupled” and similar terms related to attachment of components shall refer to attachment of two or more components that results in one, two, or more of: electrical attachment; fluid attachment; magnetic attachment; mechanical attachment; optical attachment; sonic attachment; and / or other operable attachment arrangements. The operable attachment of two or more components can facilitate the transmission between the two or more components of: power; signals; electrical energy; fluids or other flowable materials; magnetism; mechanical linkages; light; sound such as ultrasound; and / or other materials and / or components.

[0053]

[0044] It will be further understood that when a first element is referred to as being "in", "on" and / or "within" a second element, the first element can be positioned: within an internal space of the second element, within a portion of the second element (e.g. within a wall of the second element); positioned on an external and / or internal surface of the second element; and combinations of one or more of these.

[0054]

[0045] As used herein, the term “proximate”, when used to describe proximity of a first component or location to a second component or location, is to be taken to include one or more locations near to the second component or location, as well as locations in, on and / or within the second component or location. For example, a component positioned proximate an anatomical site (e.g. a blood or other fluid delivery location), shall include components positioned near to the anatomical site, as well as components positioned in, on and / or within the anatomical site.

[0046] Spatially relative terms, such as "beneath," "below," "lower," "above," "upper", “under” and the like may be used to describe an element and / or feature's relationship to another element(s) and / or feature(s) as, for example, illustrated in the figures. It will be further understood that the spatially relative terms are intended to encompass different orientations of the device in use and / or operation in addition to the orientation depicted in the figures. For example, if the device in a figure is turned over, elements described as "below" and / or "beneath" other elements or features would then be oriented "above" the other elements or features. The device can be otherwise oriented (e.g. rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Attomey Docket No. ARC-001 -PCT

[0055]

[0047] The terms “reduce”, “reducing”, “reduction” and the like, where used herein, are to include a reduction in a quantity, including a reduction to zero. Reducing the likelihood of an occurrence shall include prevention of the occurrence. Correspondingly, the terms “prevent”, “preventing”, and “prevention” shall include the acts of “reduce”, “reducing”, and “reduction”, respectively.

[0056]

[0048] The term "and / or’’ where used herein is to be taken as specific disclosure of each of the two specified features or components with or without the other. For example "A and / or B" is to be taken as specific disclosure of each of (i) A, (ii) B and (iii) A and B, just as if each is set out individually herein.

[0057]

[0049] The term “one or more”, where used herein can mean one, two, three, four, five, six, seven, eight, nine, ten, or more, up to any number.

[0058]

[0050] The terms “and combinations thereof’ and “and combinations of these” can each be used herein after a list of items that are to be included singly or collectively. For example, a component, process, and / or other item selected from the group consisting of: A; B; C; and combinations thereof, shall include a set of one or more components that comprise: one, two, three or more of item A; one, two, three or more of item B; and / or one, two, three, or more of item C.

[0059]

[0051] In this specification, unless explicitly stated otherwise, “and” can mean “or”, and “or” can mean “and”. For example, if a feature is described as having A, B, or C, the feature can have

[0060] A, B, and C, or any combination of A, B, and C. Similarly, if a feature is described as having A,

[0061] B, and C, the feature can have only one or two of A, B, or C.

[0062]

[0052] As used herein, when a quantifiable parameter is described as having a value “between” a first value X and a second value Y, it shall include the parameter having a value of: at least X, no more than Y, and / or at least X and no more than Y. For example, a length of between 1 and 10 shall include a length of at least 1 (including values greater than 10), a length of less than 10 (including values less than 1), and / or values greater than 1 and less than 10.

[0063]

[0053] The expression “configured (or set) to” used in the present disclosure may be used interchangeably with, for example, the expressions “suitable for”, “having the capacity to”, “designed to”, “adapted to”, “made to” and “capable of’ according to a situation. The expression “configured (or set) to” does not mean only “specifically designed to” in hardware. Attorney Docket No. ARC-001 -PCT

[0064] Alternatively, in some situations, the expression “a device configured to” may mean that the device “can” operate together with another device or component.

[0065]

[0054] As used herein, the terms “about” or “approximately” shall refer to ± 20% of a stated value.

[0066]

[0055] As used herein, the term “threshold” refers to a maximum level, a minimum level, and / or range of values correlating to a desired or undesired state. In some embodiments, a system (e.g., a manufacturing system) and / or process parameter is maintained above a minimum threshold, below a maximum threshold, within a threshold range of values, and / or outside a threshold range of values, such as to cause a desired effect and / or to prevent or otherwise reduce (hereinafter “prevent”) an undesired event. In some embodiments, a system and / or process parameter is maintained above a first threshold (e.g. above a first temperature, pressure, temporal, and / or other threshold to cause a desired effect) and below a second threshold (e.g. below a second temperature, pressure, temporal, and / or other threshold to prevent an undesired effect). In some embodiments, a threshold value is determined to include a safety margin, such as to account for material, equipment, operator, and / or other parameter variability, system variability, tolerances, and the like. As used herein, “exceeding a threshold” relates to a parameter going above a maximum threshold, below a minimum threshold, within a range of threshold values and / or outside of a range of threshold values.

[0067]

[0056] As described herein, “room pressure” shall mean pressure of the environment surrounding the systems and devices of the present inventive concepts. Positive pressure includes pressure above room pressure or simply a pressure that is greater than another pressure, such as a positive differential pressure across a fluid pathway component such as a valve. Negative pressure includes pressure below room pressure or a pressure that is less than another pressure, such as a negative differential pressure across a fluid component pathway such as a valve. Negative pressure can include a vacuum but does not imply a pressure below a vacuum. As used herein, the term “vacuum” can be used to refer to a full or partial vacuum, or any negative pressure as described hereabove.

[0068]

[0057] The term “diameter” where used herein to describe a non-circular geometry is to be taken as the diameter of a hypothetical circle approximating the geometry being described. For example, when describing a cross section, such as the cross section of a component, the term Attorney Docket No. ARC-001 -PCT

[0069] “diameter” shall be taken to represent the diameter of a hypothetical circle with the same cross sectional area as the cross section of the component being described.

[0070]

[0058] The terms “major axis” and “minor axis” of a component where used herein are the length and diameter, respectively, of the smallest volume hypothetical cylinder which can completely surround the component.

[0071]

[0059] As used herein, the term “functional element” is to be taken to include one or more elements constructed and arranged to perform a function. A functional element can comprise a sensor and / or a transducer. In some embodiments, a functional element is configured to deliver energy. Alternatively or additionally, a functional element (e.g. a functional element comprising a sensor) can be configured to record one or more parameters, such as a parameter of a manufacturing system, a parameter of a process (e.g., a manufacturing process), and / or a parameter of a product to be produced by a manufacturing system. In some embodiments, a sensor or other functional element is configured to perform a diagnostic function (e.g. to gather data used to perform a diagnosis). In some embodiments, a functional element is configured to perform a manufacturing function (e.g. to modify and / or move a material). In some embodiments, a functional element comprises one or more elements constructed and arranged to perform a function selected from the group consisting of: deliver energy; extract energy (e.g. to cool a component); manipulate a system component; record or otherwise sense a parameter such as a product, process, and / or a system parameter; and combinations of one or more of these. A functional element can comprise a fluid and / or a fluid delivery system (e.g., a gas or liquid delivery system). A “functional assembly” can comprise an assembly constructed and arranged to perform a function, such as a diagnostic and / or manufacturing function. A functional assembly can comprise one or more functional elements.

[0072]

[0060] The term “transducer” where used herein is to be taken to include any component or combination of components that receives energy or any input, and produces an output. In some configurations, a transducer converts an electrical signal into any output, such as: light (e.g. a transducer comprising a light emitting diode or light bulb), sound (e.g. a transducer comprising a piezo crystal configured to deliver ultrasound energy); pressure (e.g. an applied pressure or force); heat energy; cryogenic energy; chemical energy; mechanical energy (e.g. a transducer comprising a motor or a solenoid); magnetic energy; and / or a different electrical signal (e.g. different than the input signal to the transducer). Alternatively or additionally, a transducer can Attorney Docket No. ARC-001 -PCT convert a physical quantity (e.g. variations in a physical quantity) into an electrical signal. A transducer can include any component that delivers energy and / or an agent, such as a transducer configured to deliver one or more of: electrical energy (e.g. a transducer comprising one or more electrodes); light energy (e.g. a transducer comprising a laser, light emitting diode and / or optical component such as a lens or prism); mechanical energy (e.g. a transducer comprising a manipulating element); sound energy (e.g. a transducer comprising a piezo crystal); chemical energy; electromagnetic energy; magnetic energy; and combinations of one or more of these.

[0061] As used herein, the term “fluid” can refer to a liquid, gas, gel, or any flowable material, such as a material which can be propelled through a lumen and / or opening.

[0073]

[0062] As used herein, the term “material” can refer to a single material, or a combination of two, three, four, or more materials.

[0074]

[0063] As used herein, the term “user interface” can comprise one or more interfaces, each interface comprising one or more components configured to receive an input from a user, “user input device” herein, and / or one or more components configured to provide output to a user, “user output device” herein. A user input device and a user output device can each comprise a component that is part of another device (e.g. a button that is part of a console or a speaker that is part of a console).

[0075]

[0064] The terms “data” and “information” are used interchangeably herein.

[0076]

[0065] It is appreciated that certain features of the inventive concepts, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the inventive concepts which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination. For example, it will be appreciated that all features set out in any of the claims (whether independent or dependent) can be combined in any given way.

[0077]

[0066] It is to be understood that at least some of the figures and descriptions of the inventive concepts have been simplified to focus on elements that are relevant for a clear understanding of the inventive concepts, while eliminating, for purposes of clarity, other elements that those of ordinary skill in the art will appreciate may also comprise a portion of the inventive concepts. However, because such elements are well known in the art, and because they do not necessarily Attorney Docket No. ARC-001 -PCT facilitate a better understanding of the inventive concepts, a description of such elements is not provided herein.

[0078]

[0067] Terms defined in the present disclosure are only used for describing specific embodiments of the present disclosure and are not intended to limit the scope of the present disclosure. Terms provided in singular forms are intended to include plural forms as well, unless the context clearly indicates otherwise. All of the terms used herein, including technical or scientific terms, have the same meanings as those generally understood by an ordinary person skilled in the related art, unless otherwise defined herein. Terms defined in a generally used dictionary should be interpreted as having meanings that are the same as or similar to the contextual meanings of the relevant technology and should not be interpreted as having ideal or exaggerated meanings, unless expressly so defined herein. In some cases, terms defined in the present disclosure should not be interpreted to exclude the embodiments of the present disclosure.

[0079]

[0068] Transporting electricity through metal conductors is the most prevalent mechanism for energy transfer today, and is poised to grow significantly with increased electrification of the industrial, transportation, building sectors, and data centers with the advent of artificial intelligence. Reducing the energy loss in conductors as achieved in the enhanced materials of the present inventive concepts, improves the efficiency of electrical transport and reduces associated energy production emissions. Better conductors will be critical for power transmission in a more distributed grid as renewable energies like solar and wind become more integrated.

[0080]

[0069] In order to increase power transmission while minimizing losses, electricity must move at higher currents. Higher currents are impacted by resistance losses. As electrons pass through standard conductors, they collide and interact with atoms in the lattice, impurities, defects in the crystal structure of the material, and grain boundaries. These mechanisms hinder electron transport and result in Joule heating. Reducing resistive losses can be accomplished by increasing the cross-sectional area of the wire (invites significantly more mass) or employing a ‘band aid’ fix with an active cooling mechanism (e.g., liquid cooling, and the like). However, these solutions require a complete redesign of current energy grids to incorporate additional infrastructure (added weight, coolants, etc.) without tackling the core problem, the limitations of metals. Attorney Docket No. ARC-001 -PCT

[0081]

[0070] It is estimated that approximately 15% of all electric power generated in the US dissipates as heat during transmission through the grid due to the aforementioned Joule heating losses. The electric grid has utilized aluminum as the preferred conductor for over a century due to its superior mass-based conductivity. Aluminum transmission lines lose over 30% of their conductivity at standard operating temperatures. This issue is exacerbated by the need for the grid to expand by an additional 4 times to 10 times over the next 10 years, just to meet our increasing energy demands.

[0082]

[0071] Provided herein are enhanced materials, such as metals that are infused with carbon nanomaterials. Also provided herein are manufacturing systems and manufacturing methods for producing enhanced materials, as well as products that include these enhanced materials.

[0083]

[0072] In the field of material science and additive manufacturing, there has been a constant effort to improve the performance of materials such as metals for various applications, such as industrial applications. Copper and aluminum are widely used in electric motors, power transmission lines, and other devices and systems (“devices” or “systems” herein) where the thermal and electrical conductivity of these metals, as well as their mechanical strength, are key factors. However, traditional copper and aluminum possess inherent limitations in terms of conductivity, mechanical strength, and thermal dissipation. The manufacturing systems and methods of the present inventive concepts produce enhanced materials which overcome these and other limitations. These enhanced materials can exhibit improved electrical properties, mechanical properties, and / or thermal properties, as compared to currently available nonenhanced similar materials.

[0084]

[0073] Referring now to Fig. 1, a block diagram of an enhanced material is illustrated, consistent with the present inventive concepts. As shown in Fig. 1, an enhanced material, EM 100 can comprise a combination of “source materials”, such as source materials comprising at least a base material 110, and an additive material, 120, each as shown in Fig. 1. Base material 110 can comprise a metal, such as aluminum, copper, nickel, steel, a metal alloy, and / or other metal. Additionally, or alternatively, base material 110 can comprise a non-metal.

[0085] Additive material 120 can comprise one or more materials (e.g., one or more non-metals, metals, or both). In some embodiments, additive material 120 comprises a carbon nanomaterial, such as Attorney Docket No. ARC-001 -PCT graphene and / or carbon nanotubes. An additive material 120 comprising a carbon nanomaterial can be utilized in producing an EM 100 based on the superior material properties of carbon nanomaterials.

[0086]

[0074] In some embodiments, base material 110 comprises copper, and in combination with additive material 120 (e.g., a carbon nanomaterial) can be processed as described herein to achieve various enhancements, such as improved electrical conductivity. For example, an EM 100 can be produced and used in electric motors, transformers, and / or other conductor-based assemblies (e.g., assembly 310 described herein), where EM 100 and / or the associated assembly achieve a benefit (e.g., as compared to standard materials or assemblies with standard materials) selected from the group consisting of: increased or otherwise improved electrical conductivity; stronger or otherwise improved magnetic fields produced; reduced Joule heating losses, enhanced heat dissipation and / or otherwise improved thermal property; more efficient cooling (e.g., of stator motor windings); increased tensile and / or other mechanical strength; reduced density and / or weight; higher efficiency; and combinations of these.

[0087]

[0075] In some embodiments, base material 110 comprises aluminum, and in combination with additive material 120 (e.g., a carbon nanomaterial) can be processed as described herein to achieve various enhancements, such as improved electrical conductivity. For example, an EM 100 can be produced and used in electric motors, transformers, and / or other conductor-based assemblies (e.g., assembly 310 described herein), where EM 100 and / or the associated assembly achieve a benefit (e.g., as compared to standard materials or assemblies with standard materials) selected from the group consisting of: increased or otherwise improved electrical conductivity; stronger or otherwise improved magnetic fields produced; reduced Joule heating losses, enhanced heat dissipation and / or otherwise improved thermal property; more efficient cooling (e.g., of stator motor windings); increased tensile and / or other mechanical strength; reduced density and / or weight; higher efficiency; and combinations of these.

[0088]

[0076] In some embodiments, base material 110 comprises aluminum, and the combination with additive material 120 (e.g., a carbon nanomaterial) results in an EM 100 that can be used in power transmission lines with significantly improved performance, such as by increasing wire ampacity, reducing Joule heating losses, improving mechanical strength (leading to reduced sag in transmission wires), and creating lighter transmission lines (e.g., lighter wire conductors) with Attorney Docket No. ARC-001 -PCT increased performance (e.g., due to the lower density of carbon nanomaterials than base material 110).

[0089]

[0077] In some embodiments, base material 110 comprises aluminum that is functionalized with copper, nickel, or both, such as to increase the solubility of carbon in the aluminum (e.g., to promote the growth of carbon nanomaterials via chemical vapor deposition (“CVD”)).

[0090]

[0078] EM 100 can be of similar construction and arrangement to EM 100 described in reference to Fig. 1 A. EM 100 can be produced using a manufacturing system as described in reference to Fig. 2 and / or otherwise as described herein. EM 100 can be produced as described in reference to Figs. 3 and / or 3 A through 3E, and / or otherwise as described herein. EM 100 can be included in a product (e.g., a consumer or commercial product), such as is described in reference to Fig. 4 and / or otherwise as described herein.

[0091]

[0079] Referring additionally to Fig. 1A, a block diagram of an embodiment of enhanced material EM 100 is illustrated, consistent with the present inventive concepts. EM 100 can include one, two, or more of the components and / or configurations shown in Fig. 1 A.

[0092]

[0080] In some embodiments, the source materials configured to produce EM 100 further comprise an additional material, second additive material 160 shown. Second additive material 160 can comprise a metal, a non-metal, or both. In some embodiments, second additive material 160 comprises a type of metal that is not included in additive material 120.

[0093]

[0081] In some embodiments, EM 100 comprises an outer layer, cover 101 shown, that comprises second additive material 160, but does not include additive material 120. For example, additive material 120 can comprise a carbon nanomaterial (e.g., flakes of graphene or carbon nano tubes) that are encapsulated by a cover 101 comprising second additive material 160, such that additive material 120 is not exposed to air and / or other environmental conditions during the use of EM 100 (e.g., to prevent oxidation and / or other undesired modification of additive material 120 as integrated in EM 100).

[0094]

[0082] In some embodiments, EM 100 is produced using one or more processing materials, processing materials 250 described herein. Attorney Docket No. ARC-001 -PCT

[0095]

[0083] In some embodiments, EM 100 comprises a structure that includes both a base material 110 (e.g., aluminum or other metal) and an additive material 120 (e.g., a carbon nanomaterial), that can be provided in a wire form for electrical power transmission lines. In these transmission line applications, EM 100 can exhibit reduced power losses as compared with state-of-the-art (SOA) transmission lines, such as to reduce energy losses by at least 25%, 35%, 45%, or 50% as compared to SOA transmission lines (e.g., due to a correlating reduction in Joule heating loss). This improved efficiency can correlate to eliminating over 800M tonnes of carbon dioxide (CO2) emissions every year in the United States. Electrical conductors (e.g., wires) comprising EM 100 can provide at least a 25%, 35%, 45%, and / or 50% increase in electrical conductivity, thermal conductivity, or both, as compared to SOA conductors. Electrical conductors comprising EM 100 can provide at least a 4X, 6X, 8X and / or 1 OX improvement in mechanical strength as compared to SOA conductors. As compared to SOA conductors, conductors comprising EM 100 can provide at least 3X, 4X, or 5X higher electrical conductivity, at least 0.8X, 1.4X, and / or 2X higher thermal conductivity; and / or at least 200X, 300X, 400X, and / or 500X higher mechanical strength. EM 100 can comprise a unique carbon composite wire architecture, such as when produced using an additive (laser melt) process that infuses base material 110 (e.g., a powder of aluminum or other metal) with additive material 120 (e.g., carbon nanomaterials) to scalably print an EM 100 in any shape, gauge, or length wire. Grid-scale deployment of conductors incorporating EM 100 has the potential to save at least 100 billion kWh , 200 billion kWh, and / or 300 billion kWh of energy per year equating to an annual savings of $50 billion.

[0096]

[0084] The rapidly growing demand for electric vehicles and data centers is stressing the already aged and overburdened U.S. power grid. Traditional aluminum wire, the mainstay of power transmission since the late 1800s, is now a bottleneck for power transmission, losing over 30% of its conductivity at operating temperatures for power transmission (100°C to 210°C). Grid-scale deployment of EM 100 (e.g., when configured as an aluminum-carbon nanomaterial wire) has the potential to save over 300 billion kWh of energy per year equating to an annual savings of $50 billion. EM 100 enables unprecedented power transmission efficiency via massive reduction in Joule heating losses (e.g., 50%). Use of EM 100 can result in expanding Attorney Docket No. ARC-001 -PCT grid capacity by a factor of four to ten over the next decade, while minimizing raw material and deployment costs (80% lower cost / mile compared to SOA).

[0097]

[0085] In some embodiments, EM 100 comprises a material that includes at least a 1.5%, 2.5%, 3.5%, 4.0%, 4.5%, or 5% proportion by weight of additive material 120 (e.g., a carbon nanomaterial). The inclusion of additive material 120 can improve one or more benefits selected from the group consisting of: electrical conductivity; thermal conductivity; mechanical strength; and combinations of these. Alternatively, or additionally, EM 100 can comprise a material that includes no more than 30%, no more than 20%, no more than 15%, and / or no more than 10% proportion by weight of additive material 120 (e.g., a carbon nanomaterial), such as to limit stiffness of EM 100 (e.g., when in the form of a wire or rod), limit cost, limit defect density, and / or limit fatigue thresholds. In some embodiments, EM 100 comprises a material comprising base material 110 (e.g., aluminum, copper, or other metal) and additive material 120 (e.g., carbon nanomaterials), wherein the percentage by weight of additive material 120 is approximately 5%, and, as compared to the base material 110 alone, the EM 100 has approximately a 50% enhanced electrical conductivity, at least a 50% enhanced thermal conductivity, and 10X increase in mechanical strength. EM 100 can have additional enhancements as compared to its base material 110, such as: decreased density (weight reduction); lower coefficient of thermal expansion (CTE); stronger material contacts; increased wear resistance (reference Table 1); and combinations of one, two or more of these. Carbon nanomaterials have nearly five (5) times the conductivity of aluminum, and maintain this conductivity at elevated temperatures (100°C to 240°C). This conductivity performance correlates to a carbon nanomaterial-based EM 100 with Joule heating losses cut in half as compared to the base material 110 alone.

[0098]

[0086] As illustrated below, Table 1 outlines various performance metrics achievable with EM 100.

[0099] Attorney Docket No. ARC-001 -PCT

[0100] Table 1

[0101]

[0087] Fig. 8 showcases the sag reduction provided by EM 100. Carbon nanomaterials are nearly 100 times stronger than aluminum, and do not succumb to the same electro migration issues that metals have; therefore an EM 100 constructed and arranged as a transmission wire will reduce both transmission line degradation and increase structural integrity, which results in a reduction in points of failure (e.g., downed power lines, wildfires, and other significant issues). Furthermore, this increased strength would result in less sagging in transmission lines. Note that the ACCS wire shown is the industry standard. The enabling of more efficient energy transmission provided by EM 100, coupled with reduced heat generation, improved conductivity, and mechanical strength, demonstrates that EM 100 can significantly optimize the performance of power transmission infrastructure.

[0102]

[0088] Competing materials such as traditional copper or aluminum alloys lack the combination of conductivity, thermal efficiency, and mechanical strength found in EM 100. While copper offers high conductivity, it is significantly heavier and more expensive, limiting its use for large-scale grid applications. Aluminum alloys, meanwhile, cannot match the mechanical strength of EM 100 comprising carbon nano materials. Both aluminum and copper have significant reduction in conductivity at high temperatures.

[0103]

[0089] Referring additionally to Fig. 2, a manufacturing system for producing an enhanced material is illustrated, consistent with the present inventive concepts. Manufacturing system 200 of Fig. 2 is configured to process source materials (e.g., at least base material 110 and additive material 120) to produce an enhanced material, EM 100, such as is described in reference to Attorney Docket No. ARC-001 -PCT

[0104] Figs. 1 and 1A, and / or otherwise herein. Manufacturing system 200 of Fig. 2 is configured to perform one or more manufacturing processes for producing EM 100, such as those described in reference to Figs. 3, 3A, 3B, 3C, 3D, 3E, and / or otherwise herein. Manufacturing system 200 can be configured to produce an intermediate material, IM 100’ (e.g., as described in reference to Fig. 1 A), which comprises a material that requires further processing to produce EM 100. As used herein, the term IM 100’ can refer to the material produced as a result of any one, two, or more manufacturing steps that are a subset of all the processing steps used to produce EM 100. As used herein, reference to EM 100 can also refer to IM 100’ (e.g., a material that required additional processing to achieve EM 100), in other words IM 100’ and EM 100 can be used synonymously.

[0105]

[0090] Manufacturing system 200 can comprise processing equipment 210 shown. Processing equipment 210 can comprise one, two, or more of the pieces of equipment shown in Fig. 2 and described herein.

[0106]

[0091] Processing equipment 210 can comprise mixer 211 shown. Mixer 211 can comprise one or more components selected from the group consisting of: a ball mill; a high-energy mixer; an ultrasonication device; a bath sonication device; and combinations of these. Mixer 211 can be configured to mix base material 110 (e.g., aluminum powder, copper powder, or both) with additive material 120 (e.g., carbon nanomaterials such as graphene or carbon nanotubes). Ball milling or high-energy mixing using mixer 211 ensures the additive material 120 is uniformly dispersed within the base material matrix (e.g., aluminum and / or copper matrix), such as to enhance conductivity and mechanical properties. Mixer 211 can be configured to combine base material 110 and additive material 120 via a rotation, such as rotation at high speed, in the mixer. Mixer 211 can employ one, two, or more grinding elements (e.g., balls or other mechanical elements) to break up and mix the materials into a homogeneous composite powder.

[0107]

[0092] Processing equipment 210 can comprise CVD 212 shown. CVD 212 can comprise a chemical vapor deposition system. CVD 212 can be configured to apply a controlled, thin layer of additive material 120 (e.g., carbon nanomaterial) onto base material 110 (e.g., aluminum wire or powder, copper wire or powder, or both), ensuring strong adhesion between the two materials. CVD 212 can be configured to “grow” (e.g., additively deposit) additive material 120 (e.g., graphene) from the bottom up. CVD 212 can perform plasma spraying, where a plasma arc generates a high-temperature stream that deposits a thin layer of additive material 120 (e.g., a Attorney Docket No. ARC-001 -PCT nanomaterial) onto the surface of base material 110. Alternatively, or additionally, CVD 212 can use a controlled atmosphere to coat base material 110 with additive material 120.

[0108]

[0093] Processing equipment 210 can comprise first furnace 213 shown. First furnace 213 can comprise an induction furnace, such as an induction furnace which is configured to melt base material 110 while preserving the structure and distribution of additive material 120 (e.g., carbon nano materials) within the molten metal. In use, powder composites of base material 110 and additive material 120 (e.g., carbon nanomaterial) are placed in first furnace 213, which can be configured to use electromagnetic induction to heat and melt the composites. Control of temperature ensures the additive material 120 are preserved and evenly distributed when casting or extruding IM 100’ and / or EM 100.

[0109]

[0094] Processing equipment 210 can comprise compactor 214 shown. Compactor 214 can comprise a powder compactor, a cold isostatic press, or both. Compactor 214 can densify a powder mixture of base material 110 and additive material 120 into a solid billet for further processing, increasing its mechanical stability. In use, compactor 214 applies high pressure (e.g., uniaxial or isostatic pressure) to the powder mixture, forming a billet with minimal voids and improved density.

[0110]

[0095] Processing equipment 210 can comprise extruder 215 shown. Extruder 215 can comprise an extrusion press. Extruder 215 can be configured to convert billets comprising a composite of base material 110 and additive material 120 into a wire and / or rod form (“wire” and “rod” used synonymously herein), imparting directional strength and conductivity. Extruder 215 can heat the billet to a temperature where it becomes malleable, then pushed through a die to produce a continuous rod with enhanced properties. The high pressure and heat provided by extruder 215 also help align the additive material 120 (e.g., carbon nanomaterials) along the length of the wire, optimizing conductivity.

[0111]

[0096] Processing equipment 210 can comprise a wire drawing machine, WDM 216 shown. WDM 216 can be configured to reduce the diameter (e.g., into a final or near-final diameter) of an extruded rod comprising both base material 110 and additive material 120, while maintaining the material's internal structure. In use, the extruder rod is pulled through progressively smaller dies in WDM 216, such as to produce a fine-gauge or other gauge rod or wire. This process performed using WDM 216 can also be configured to align the resultant material’s internal Attorney Docket No. ARC-001 -PCT structure (e.g., the internal structure of EM 100 and / or IM 100’), maintaining its mechanical strength and conductivity.

[0112]

[0097] Processing equipment 210 can comprise second furnace 217 shown (e.g., as an alternative to, or in addition to, first furnace 213). Second furnace 217 can comprise a heattreatment furnace. Second furnace 217 can be configured to alter the microstructure of a composite rod comprising base material 110 and additive material 120, such as to relieve stress and / or enhance final material properties, like conductivity and thermal stability. In use, a composite rod comprising base material 110 and additive material 120 is heat-treated using second furnace 217, at controlled temperatures. This heat-treating aligns the base material 110 structure (e.g., crystal structure) and enhances the stability of the additive material 120 (e.g., carbon nanomaterials) within the matrix.

[0113]

[0098] Processing equipment 210 can comprise LPBF 218 shown. LPBF 218 can comprise a laser powder bed fusion device. LPBF 218 can perform an additive manufacturing process that builds base material 110 (e.g., metal components) in a layer-by-layer arrangement, enabling precise integration of additive material 120 (e.g., carbon nanomaterials) with base material 110, such that complex geometries and controlled material structure can be produced. In use, a powder composite including base material 110 and additive material 120 is spread in a thin layer over a build plate of LPBF 218, and a laser of LPBF 218 selectively melts areas of the powder composite (e.g., based on a CAD model). The bed then lowers slightly, and another layer of composite powder is spread. This process repeats, creating an IM 100’ and / or EM 100 with high precision and control over material distribution, ideal for specialized or customized conductor components.

[0114]

[0099] Processing equipment 210 can comprise DED 219 shown. DED 219 can comprise a directed energy deposition device configured to perform a three-dimensional (3D) printing technique (e.g., a metal 3D printing technique) that deposits material directly onto a surface. In some embodiments, DED 219 deposits the material while simultaneously melting the material, allowing for on-demand part fabrication and repair (e.g., with integrated carbon nanomaterials). In use, a mixture (e.g., a powder) comprising base material 110 and additive material 120 (e.g., carbon nano materials) is fed through a nozzle of DED 219, where a laser or electron beam of DED 219 melts the mixture as it is deposited onto the build surface. DED 219 allows for building or repairing of larger structures with precise control of additive material 120 (e.g., a Attorney Docket No. ARC-001 -PCT nanomaterial) integration, and can be used to add layers of nanomaterial-enhanced metal onto existing rod or wire components, such as to achieve tailored properties.

[0115]

[0100] Processing equipment 210 can comprise tester 220 shown. Tester 220 can comprise one or more pieces of equipment configured to perform one or more tests and / or perform one or more other diagnostic functions during the production of EM 100 (e.g., to confirm desired performance of IM 100’ and / or EM 100). Tester 220 can be configured to ensure that IM 100’ and / or EM 100 meets required conductivity, tensile strength, and thermal stability specifications. Tester 220 can comprise one or more pieces of equipment selected from the group consisting of: tensile testers; scanning electron microscopes (SEM); Raman spectroscopy equipment; and combinations of these. Tester 220 can be configured to: confirm desired presence and arrangement of graphene, carbon nanotubes, and / or other additive material 120; perform conductivity measurements (e.g., a 4-point probe); measure thermal stability tests; and combinations of these, such as to verify the material properties, consistency, and quality of each production batch of IM 100’ and / or EM 100.

[0116]

[0101] Processing equipment 210 can comprise WAAM 221 shown. WAAM 221 can comprise a wire arc additive manufacturing device. WAAM 221 can be configured to perform a 3D printing process (e.g., a metal 3D printing process) that uses an electric arc to melt a metal wire, allowing for rapid, large-scale component fabrication with integrated additive material 120 (e.g., integrated carbon nanomaterials). In use, a composite of base material 110 and additive material 120 in wire form is fed into an arc welding head of WAAM 221, where an electric arc melts the wire and deposits it layer by layer onto a substrate. WAAM 221 is well-suited for creating large components and conductor sections, and its scalability makes it ideal for producing thicker, high-strength segments of IM 100’ and / or EM 100. Additionally, WAAM 221 is configured to allow for adjustments in additive material 120 distribution (e.g., carbon nanomaterial distribution) during deposition, optimizing performance properties like conductivity and mechanical strength across the structure of IM 100’ and / or EM 100.

[0117]

[0102] Processing equipment 210 can comprise atomizer 222 shown. Atomizer 222 can comprise a powder gas atomizer. Atomizer 222 can be configured to produce a fine, spherical powder comprising base material 110 that has been infused with additive material 120, ensuring uniform particle size and distribution for consistent quality in additive manufacturing and powder metallurgy process. In use, a composite of base material 110 and additive material 120 Attorney Docket No. ARC-001 -PCT is in a molten state, and is ejected through a nozzle of atomizer 222, where a high-pressure gas (often nitrogen or argon) rapidly cools and breaks the composite into fine, spherical particles. This method allows for creation of a powder with highly controlled particle size, essential for ensuring even dispersion of additive material 120. This high-quality powder is then processed using LPBF 218, DED 219, and / or other processing equipment to create an IM 100’ and / or EM 100 (e.g., in the form of wire and / or rod conductor components) with uniform, predictable properties.

[0118]

[0103] Processing equipment 210 can comprise an additive printer (e.g., DED 219), which has an inlet configured for a controlled mixture of a hydrocarbon precursor, forming gas, and inert gas (e.g., argon) that is used during a laser exposure (e.g., to replicate a laser-assisted CVD process).

[0119]

[0104] Manufacturing system 200 can comprise processing materials 250 shown.

[0120] Processing materials 250 can comprise one, two, or more materials used to perform one or more processing steps to create IM 100’ and / or EM 100 (e.g., but not included in the final structure of EM 100). Processing material 250 can comprise one, two, or more materials selected from the group consisting of: argon, nitrogen, hydrogen, methane, and / or other gas; a gas used to apply a force to move a material; a gas used to cool a material or a component of manufacturing system 200; a gas used to force material through a nozzle; a precursor gas such as methane or other carbon-based precursor gas; a forming gas (e.g., a gas comprising 95% hydrogen and 5% argon); an inert gas; a surfactant; and combinations of these.

[0121]

[0105] Manufacturing system 200 can comprise console 270 shown. Console 270 can comprise one, two, or more consoles. Console 270 can comprise a console configured to control one or more processes performed by manufacturing system 200, such as when console 270 comprises one, two, or more consoles configured to control one, two, or more pieces of equipment of processing equipment 210.

[0122]

[0106] Console 270, and / or another component of manufacturing system 200 can include one or more user interfaces, user interface 275 shown. User interface 275 can provide and / or receive information to and / or from a user of the system (e.g., a factory worker or other operator using manufacturing system 200 to produce EM 100). User interface 275 can include one or more user input devices and / or output devices. For example, user interface 275 can comprise a Attorney Docket No. ARC-001 -PCT keyboard, mouse, touchscreen, and / or other human interface or other input device. In some embodiments, user interface 275 can comprise a speaker, indicator light, haptic transducer and / or other human interface or other output device (e.g., as described herein). In some embodiments, a user output device comprises a video output device, such as a display. A display can comprise a touchscreen display, for example when a user input device and a user output device collectively comprise a display. In some embodiments, a processing unit 280 (e.g., as described herein) is configured to provide an interactive graphical user interface, such as a graphical user interface provided by an application 286 (e.g., as described herein). A GUI can be displayed (e.g., displayed to a user of manufacturing system 200) via a display. In some embodiments, user interface 275 and / or a GUI of user interface 275 comprise a virtual reality and / or augmented reality interface. One or more components of manufacturing system 200 can comprise one or more portions of a user interface 275, such as console 270, and / or other components of manufacturing system 200 described herein.

[0123]

[0107] Console 270 (and / or other components of manufacturing system 200) can include one or more communication modules, communication module 271 shown. Communication module 271 can be configured to provide communication between (e.g., transfer commands, and / or other data between) two or more components of manufacturing system 200, such as via wired and / or wireless communication. For example, communication module 271 can include one or more transmitters and / or receivers. A transceiver can comprise a wireless transceiver, such as a Bluetooth transceiver, a Near Field Communication (NFC) transceiver, a Wi-Fi transceiver, a cellular transceiver, a satellite-connected transceiver, and / or other short-range and / or long-range wireless transceiver. In some embodiments, communication module 271 is configured to communicate via one or more wired and / or wireless networks, such as network 290 shown. Network 290 can include a wireless network, such as cellular network, LAN, WAN, VPN, the Internet, and / or other wireless network connecting two or more devices. In some embodiments, network 290 comprises a wired network, and / or a network including wired and wireless devices.

[0124]

[0108] Manufacturing system 200 can comprise one or more data processing modules, processing unit 280 shown, that can be configured to perform and / or facilitate one or more of the functions of manufacturing system 200 described herein. For example, processing unit 280 Attorney Docket No. ARC-001 -PCT can perform and / or facilitate one or more processes, data collections, data analyses, data transfers, and / or signal processing functions, and / or other functions of manufacturing system 200 (“functions of manufacturing system 200” or “system functions” herein). Processing unit 280 can be used to monitor, control, or both monitor and control one or more manufacturing processes, such as one or more manufacturing processes selected from the group consisting of: a melting process; a heating process; a cooling process; a material manipulation process; a printing process such as a 3D printing process; a surfactant-applying process; and combinations of one or more of these. Processing unit 280 can comprise one or more electronic elements, electronic assemblies, and / or other electronic components, such as components selected from the group consisting of: microprocessors; microcontrollers; state machines; memory storage components; analog-to-digital converters; rectification circuitry; filters and other signal conditioners; sensor interface circuitry; transducer interface circuitry; and combinations of one, two, or more of these. For example, processing unit 280 can include at least one processor and at least one memory storage component, such as processor 281 and memory 282, each shown. Memory 282 can be coupled to processor 281, and memory 282 can store one or more sets of computer instructions, instructions 283 shown. Instructions 283 can comprise instructions used by processor 281 to perform one or more algorithms of manufacturing system 200. For example, manufacturing system 200 can comprise one or more algorithms, algorithm 285 shown, that are performed by processor 281. Additionally, or alternatively, instructions 283 can comprise instructions for running one or more applications of manufacturing system 200, for example application 286 shown. Processing unit 280 can be configured to “run” application 286, for example such that application 286 can control one or more parameters of a manufacturing method (e.g., method 1000, 1000a, 1000b, 1000c, lOOOd, and / or lOOOe described herein) and / or manufacturing system 200. In some embodiments, application 286 is configured to receive input from a user of manufacturing system 200, for example via a user interface (e.g., user interface 275 described herein). In some embodiments, algorithm 285 can comprise one or more machine learning, neural net, and / or other artificial intelligence algorithms (“Al algorithm” herein). All or a portion of one or more processing units 280 can be integrated into one, two, or more of the various components of manufacturing system 200, such as console 270, a server (e.g., server 295 described herein), and / or other component of manufacturing system 200. In some embodiments, one or more consoles of console 270 comprise processing unit 280. Attorney Docket No. ARC-001 -PCT

[0125]

[0109] In some embodiments, algorithm 285 comprises an Al algorithm and / or other algorithm configured to monitor the production of EM 100 (e.g., monitor one or more processes of method 1000 and / or monitor one or more components of manufacturing system 200). In these embodiments, algorithm 285 (e.g., an Al algorithm) can be configured to adjust one or more process parameters and / or manufacturing system parameters (e.g., processing equipment 210 parameters), for example an adjustment that is performed in a single process (e.g., in a closed- loop arrangement during the single process), and / or an adjustment that is performed between a first production of EM 100 and a second production of EM 100 (e.g., an algorithm configured to routinely improve the quality of EM 100 that is produced over time).

[0126]

[0110] In some embodiments, manufacturing system 200 includes one or more servers, server 295 shown, that can each be configured to provide data storage and / or data processing for the providers of manufacturing system 200 (e.g., the manufacturer and / or distributor of manufacturing system 200) and / or the users of manufacturing system 200. As used herein, data processing can refer to the receiving of data, processing of data, transmission of data (e.g., transmitting the results of data processing), and / or the storage of data. Server 295 can comprise one or more processing units 280. Additionally, or alternatively, server 295 can include one or more data storage units for storing data collected by manufacturing system 200, data 296 shown. Server 295 can comprise an “off-site” server (e.g., remotely located from the users of manufacturing system 200), such as a server owned, maintained, and / or otherwise provided by the provider of manufacturing system 200. Alternatively, or additionally, server 295 can comprise a cloud-based server.

[0127]

[0111] Manufacturing system 200 can comprise functional element 299 shown. Functional element 299 can comprise one, two, or more functional elements and / or functional assemblies. Functional element 299 can comprise one, two, or more sensors, and / or one, two, or more transducers. In some embodiments, functional element 299 comprises one, two, or more temperature sensors, one, two or more pressure sensors, and / or one, two, or more other sensors, these sensors configured to monitor a parameter of IM 100’ and / or EM 100, and / or a parameter of a component of processing equipment 210 (e.g., such as to perform method 1000 in a closed- loop arrangement). Attorney Docket No. ARC-001 -PCT

[0128]

[0112] Referring additionally to Fig. 3, a flow chart of a method 1000 of manufacturing the enhanced material, EM 100, of Fig. 1 is illustrated, consistent with the present inventive concepts Infusing additive material 120 (e.g., carbon nanomaterials) into a base material 110 using method 1000, and / or other manufacturing methods as described herein (e.g., as shown in Figs. 3 A through 3E) can improve (e.g., amplify) the electrical, thermal, and / or mechanical properties of the base material 110 (e.g., a metal). Current manufacturing methods are inadequate in achieving effective integration, especially during the additive manufacturing of metal components. The manufacturing systems and method of the present inventive concepts achieves effective integration of the materials.

[0129]

[0113] In STEP 1100, source materials comprising base material 110, additive material 120, and any other materials, tools, or other items required to produce EM 100 are gathered, procured, collected, and / or otherwise obtained (“obtained” herein).

[0130]

[0114] In STEP 1200, at least base material 110 and additive material 120 are processed to produce EM 100. Processing of STEP 1200 can comprise one or more processing steps, such as those described in reference to Figs. 3 A through 3E and / or otherwise herein.

[0131]

[0115] STEP 1200 can comprise an additive manufacturing (AM) process.

[0132]

[0116] STEP 1200 can comprise real-time carbon nanomaterial infusion or powder infusion. In STEP 1200, precise control of nanoscale material properties is used, such as material mixture and composition properties, as well as carbon density and orientation.

[0133]

[0117] STEP 1200 can comprise infusing an additive material 120 comprising carbon nanomaterials into a base material 110 comprising aluminum, copper, and / or other metal. STEP 1200 can comprise the infusing of carbon nanomaterials via one, two, or three of the following methods: (1) via powder mixing with ball milling or ultrasonication; (2) CVD infusion of carbon nanomaterials into the powder or (3) modified commercial additive manufacturing (AM) process with laser-assisted CVD to infuse carbon nanomaterials at the time of metal printing. A laser melt process can be used to fabricate EM 100 (e.g., in wire form). Additive (metal 3D) printing can be used to produce metal (e.g., aluminum) infused with carbon nanomaterials, such as for transmission line use (reference Fig. 6). Attorney Docket No. ARC-001 -PCT

[0134]

[0118] In some embodiments, STEP 1200 produces an intermediate material (e.g., an incompletely processed material), IM 100’ shown, which requires further processing to produce EM 100.

[0135]

[0119] In embodiments in which STEP 1200 produces the intermediate material IM 100’, as optional step, STEP 1300, can be included, in which additional processing is performed to further process IM 100’ to produce EM 100. For example, STEP 1300 can comprise applying a covering layer, cover 101 described herein, to IM 100’, where EM 100 comprises IM 100’ with the addition of cover 101 (e.g., to prevent contact of additive material 120 with air as described herein).

[0136]

[0120] In some embodiments, STEP 1200 comprises infusing an additive material 120 (e.g., an additive comprising carbon nanomaterials such as graphene, carbon nanotubes, or both) into a base material 110 comprising a metal (e.g., copper, aluminum, or both) using an additive manufacturing process. STEP 1200 can comprise a processing step in which a modified laser- assisted chemical vapor deposition (CVD) technique is used during selective laser melting (SLM) in a 3D printing process.

[0137]

[0121] STEP 1200 can include the preparation of a base material comprising a metal powder (e.g., copper or aluminum metal powder). STEP 1200 can include a 3D printing process, in which during the 3D printing process, a selective laser melts the metal powder to form the desired part. A processing material 250 comprising an inert gas (e.g., argon), can be used to prevent oxidation of the metal.

[0138]

[0122] STEP 1200 can include introducing a processing material 250 comprising a carbonbased precursor gas (such as methane) along with a processing material 250 comprising a forming gas (e.g., 95% hydrogen / 5% argon) during a laser melting step. This exposure creates the conditions for optimized laser-assisted CVD, allowing an additive material 120 comprising carbon nanomaterials to bond with a base material 110 comprising metal powder. The base material (e.g., a metal powder) is melted by a selective laser in an inert gas environment (e.g., argon), where the additive material (e.g., carbon nanomaterials) is formed and infused directly into a molten material (e.g., molten copper, aluminum, and / or other metal) as EM 100 and / or IM 100’ is being 3D printed. The result is an EM 100 and / or IM 100’ that comprises a homogeneous Attorney Docket No. ARC-001 -PCT mixture of the metal and carbon nanomaterials, with the infused properties amplified throughout the material.

[0139]

[0123] Alternatively, STEP 1200 can comprise infusing an additive material 120 (e.g., comprising carbon nanomaterials) into a base material 110 (e.g., comprising a metal powder) prior to a 3D printing process, through a separate CVD process. This configuration allows for pre-treated metal powder to be used in conventional selective laser melting systems. For example, a base material 110 comprising a metal powder can be exposed to a processing material 250 comprising a carbon-based precursor gas in a CVD chamber. The resulting infused powder is then used in a traditional selective laser melting system. This configuration allows manufacturers to use pre-infused powders in standard 3D printing machines without having to modify the gas flow or process conditions during printing.

[0140]

[0124] STEP 1200 can comprise a 3D printing process and a laser-assisted CVD process that is integrated with selective laser melting of base material 110 to infuse additive material 120 (e.g., one or more carbon nanomaterials) to produce an EM 100 comprising a metal matrix. The resultant EM 100 has improved properties (e.g., as compared to the base materials) such as improved physical, mechanical, electrical, and / or thermal properties. Base material 110 can comprise one or more metals in a powder form to which the laser-assisted CVD process is applied.

[0141]

[0125] STEP 1200 can comprise a melting of base material 110, such as a melting process using a laser. Alternatively or additionally, base material 110 can be melted using a wire arc process.

[0142]

[0126] STEP 1200 can comprise ball milling (e.g. via mixer 211) and / or ultrasonication (e.g., via mixer 211), such as using surfactants (e.g., using a processing material 250 comprising a surfactant). This method combines an additive material in a powder form (e.g., carbon nanomaterial powder) with base material 110 in a powder form (e.g., aluminum or other metal powder) via ball milling or ultrasonication. These processes can effectively homogenize (e.g., produce sufficient uniform distribution of) nanomaterials into a metal matrix (e.g., an aluminum matrix) via mechanical mixing, vibrational mixing, or both. A processing material 250 comprising a surfactant can be used to reduce the hydrophobicity mismatch between base material 110 (e.g., aluminum, copper, or other metal) and additive material 120 (e.g., a carbon Attorney Docket No. ARC-001 -PCT nanomaterial). In some embodiments, a processing material 250 comprising a surfactant can be used to “unbundle” carbon nanotubes.

[0143]

[0127] STEP 1200 can comprise a CVD infusion process in which additive material 120 (e.g., carbon nanomaterials) are grown directly on base material 110 while in a powder form (e.g., aluminum powder) via CVD (e.g., performed using CVD 212). CVD can be used to grow carbon nanomaterials on a metal (e.g., aluminum) before insertion into a laser bed for additional fabrication.

[0144]

[0128] STEP 1200 can comprise laser-assisted CVD coupled with metal printing. For example, a laser melt process can be used to fabricate an EM 100 arranged as a wire. In this method, additive material 120 comprising carbon nanomaterials can be infused at the time of metal printing by modifying a commercial AM process to integrate CVD into the melt pool. This integration allows precise control of the nanomaterial infusion, enabling real-time material engineering during EM 100 fabrication.

[0145]

[0129] STEP 1200 can comprise a powder atomization process (e.g., performed using atomizer 222). Additive material 120 (e.g., carbon nano materials) can be infused during a base material atomization process (e.g., aluminum powder atomization process), such as to increase uniformity of the distribution of additive material 120 throughout the base material 110 powder particles. In these embodiments, atomizer 222 can comprise a forming gas inlet (e.g. gas input line) and a carbon precursor gas inlet (e.g., to simulate the conditions for CVD via an atomization technique).

[0146]

[0130] STEP 1200 can comprise a laser-assisted CVD process, using CVD 212, where CVD 212 can be configured to cause in situ carbon nanomaterial growth during the laser exposure phase of additive material printing. CVD 212 can include an inlet for a controlled mixture of hydrocarbon precursors, forming gas, and inert gas. The CVD growth process can be performed during the laser exposure, achieving a homogeneous infusion of additive material 120 (e.g., carbon nanomaterials) into base material 110 (e.g., aluminum, copper, and / or other metal). In some embodiments, no more than 20 seconds, no more than 10 seconds, and / or no more than 5 seconds of carbon precursor exposure can be used to grow carbon nanomaterials.

[0147]

[0131] Method 1000 of the present inventive concepts can comprise a scalable process. Utilizing a laser melt process to additively print base material 110 (e.g., aluminum) infused with Attorney Docket No. ARC-001 -PCT additive material 120 (e.g., carbon), such as for use in transmission lines, enables the 3D printing of any gauge, shape, or length of wire to be used as a drop-in replacement for any existing wiring. In some embodiments, STEP 1200 comprises directed energy deposition (DED) metal 3D printing (e.g., using DED 219). The DED process can infuse carbon nanomaterials during an additive material phase, ensuring that the enhanced metal composite (e.g., aluminum composite) is cost-efficient and scalable, such as for widespread grid deployment. Alternatively, other processes (e.g., wire die drawing), can be used.

[0148]

[0132] Method 1000 of the present inventive concepts can be integrated into commercially available 3D printing systems, and / or used to pre-treat metal powders for various forms of additive manufacturing.

[0149]

[0133] Method 1000 of the present inventive concepts can be configured to mitigate carbon precipitation or agglomeration into graphite / aluminum carbide, such as through control of various process parameters of method 1000, and / or system parameters of manufacturing system 200 (e.g., control of these parameters during a printing process of method 1000, such as to ensure that the melt pool is properly infused with carbon nanomaterials).

[0150]

[0134] Method 1000 of the present inventive concepts can be configured to optimize carbon nanomaterial loading. This optimization is related to achieving a desired conductivity of EM 100, and involves systematically isolating and optimizing variables such as: hydrocarbon feedstock; pressure (e.g., low vs. atmospheric); partial pressure control; growth temperature; pretreatment of powder (annealing, oxidation reduction with acetic acid, and the like); cooling rate; laser exposure time; print bed temperature; and combinations of these. In some embodiments, EM 100 comprises approximately 5% by weight concentration of additive material 120 (e.g., carbon nanomaterials) in EM 100 (e.g., where base material 110 comprises aluminum).

[0151]

[0135] Method 1000 of the present inventive concepts can be configured to prevent galvanic and pitting corrosion. During processing, additive material 120 (e.g., carbon nanomaterials) are relatively homogeneously integrated and encapsulated to prevent (e.g., at least reduce) galvanic or pitting corrosion. In some embodiments, to minimize this corrosion, method 1000 will include laser cladding with aluminum. The type of aluminum or aluminum alloy used for this cladding can be tailored to improve corrosion resistance. For example, using aluminum Attorney Docket No. ARC-001 -PCT alloys that contain elements like magnesium, silicon, or zinc (which have better corrosion resistance) can be used to provide superior corrosion protection over pure aluminum.

[0152]

[0136] Method 1000 of the present inventive concepts can be configured to increase work hardening rate for wire stranding and drawing used to create EM 100. Certain manufacturing processes, such as drawing to size and wire bundling, can be difficult to achieve due to an increased stiffness of IM 100’ or EM 100 that can be caused by the inclusion of an additive material 120 comprising carbon nanomaterials. The increased stiffness may cause difficulties in drawing an EM 100 (e.g., IM 100’ or EM 100) comprising a wire to the required dimensions, potentially leading to increased defect density. Additionally, a wire-based EM 100 can have a resistance to bending which may complicate the process of winding EM 100 into tight, precise conductor bundles. These risks can be mitigated by an EM 100 that has a geometry approximating a near net shape (e.g., printing as bundle of twisted conductors), which would reduce the need for extensive deformation during manufacturing. Furthermore, alloying the EM 100 materials (e.g., base material 110, additive material 120, and / or second additive material 160) with materials such as magnesium can decrease stiffness and improve ductility, resulting in a more manageable EM 100 for these processes while maintaining the necessary performance properties.

[0153]

[0137] Method 1000 of the present inventive concepts can be configured to avoid a reduction in performance from undesired carbon nanomaterials orientation. The orientation of the carbon nanomaterials of EM 100, and / or other property of EM 100, can be configured to enhance the charge transfer through the bulk material of EM 100. In order to improve performance, method 1000 can comprise a “re-orientation” of the carbon nanomaterials, such as a process comprising a simple deformation after deposition with annealing. The principle behind this process is to re-create a shear force alignment within a melt pool by annealing and drawing a wire-based EM 100 (e.g., IM 100’) through an additional nozzle.

[0154]

[0138] Method 1000 of the present inventive concepts can be configured to avoid microfracture complications due to rigid non-binding elements such as carbon. During a melt pool solidification potential step of method 1000, microfractures and defects can result from factors such as lack of fusion or substantial thermal gradients. To mitigate these risks, method 1000 can include post-processing methods that are applied to an IM 100’ comprising a wire. This post-processing can comprise a heat treatment configured to relieve internal stresses, refine Attorney Docket No. ARC-001 -PCT the microstructure, and enhance material toughness. Additionally, post-processing can comprise hot isostatic pressing (HIP), which is highly effective in eliminating internal voids and improving material cohesion, further minimizing the risk of fractures. Alternatively, or additionally, the likelihood of defect formation can be reduced by tuning the composition of base material 110 through alloying or functionalization.

[0155]

[0139] As illustrated below, Table 2 provides a list of undesired conditions in the production of EM 100, and a method 1000 process parameter to be included and / or adjusted to prevent (e.g., or at least reduce) the undesired condition.

[0156] Attorney Docket No. ARC-001 -PCT

[0157] Table 2

[0158]

[0140] In some embodiments, method 1000 comprises one or more of the steps shown in Figs. 3A through 3E.

[0159]

[0141] In Fig. 3A, variations of method 1000, method lOOOai, lOOOaii, and lOOOaiii, are shown. Method 1000a can be performed using various feedstock materials and processing mechanisms, for example as shown in STEP 1 lOOi, STEP 1 lOOii, and STEP 1 lOOiii of Methods lOOOai, l OOOaii, and lOOOaiii, respectively. Additionally, shown in STEP 1200i, 1200ii, and / or STEP 1200iii, additive material 120 can be infused into a base material 110. In STEP HOOi of Method lOOOai, base material 110 comprises one or more solid core wires. The one or more solid core wires can comprise one or more metals such as aluminum, copper, and / or other metal. In this embodiment, additive material 120 comprises one or more gas precursors. The one or more gas precursors can comprise hydrogen, methane, and / or other gas. Following STEP 1 lOOi, method lOOOai proceeds to STEP 1200i, whereby base material 110 and additive material 120 are processed to produce EM 100 and / or IM 100’. In this embodiment, STEP 1200i can comprise powder atomization. The powder atomization can be performed using an atomizer, such as atomizer 222. STEP 1200i can be configured to infuse base material 110 with additive material Attorney Docket No. ARC-001 -PCT

[0160] 120 during the atomization process, such as to increase uniformity of the distribution of additive materials 120 throughout the base material 110 powder particles. For example, during atomization in STEP 1200i, the additive material 120 (e.g., carbon nanomaterial core) can be dispersed and integrated with the atomized metal particles. In some embodiments, atomizer 222 comprises a forming gas inlet and a carbon precursor gas inlet, such as to stimulate the conditions for CVD via an atomization technique.

[0161]

[0142] Alternatively, or additionally, as shown in STEP 1 lOOii of Method l OOOaii, one or more source materials comprising base material 110 and / or additive material 120 are obtained. In this embodiment, base material 110 comprises a powder core wire comprising a carbon nanomaterial core. The powder core wire can comprise an outer metallic sheath and an inner core. The outer metallic sheath can comprise one or more metals such as aluminum, copper, and / or other metal. The inner core can comprise additive material 120. In this embodiment, additive material 120 can comprise carbon nanomaterials. The carbon nanomaterials can comprise one or more carbon nanomaterials such as graphene, carbon nanotubes, or both. Following STEP 1 lOOii, method lOOOaii proceeds to STEP 1200ii, whereby base material 110 and additive material 120 are processed to produce EM 100 and / or IM 100’. In this embodiment, STEP 1200ii can comprise powder atomization as described hereinabove.

[0162]

[0143] Alternatively, or additionally, as shown in STEP1 lOOiii of Method lOOOaiii, one or more source materials comprising base material 110 and / or additive material 120 are obtained. In this embodiment, base material 110 can comprise atomized metal powder. The atomized metal powder can comprise one or more metals such as aluminum, copper, and / or other metal. In this embodiment, additive material 120 can comprise carbon nanomaterials. The carbon nanomaterials can comprise one or more carbon nanomaterials such as graphene, carbon nanotubes, or both. Following STEP 1 lOOiii, Method lOOOaiii proceeds to STEP 1200iii, whereby base material 110 and additive material 120 are processed to produce EM 100 and / or IM 100’. In this embodiment, STEP 1200iii can comprise mechanical functionalization milling. The mechanical functionalization milling can comprise ball milling, ultrasonication, or both. In some embodiments, mechanical functionalization milling of STEP 1200iii is performed using a mixer, such as mixer 211. The mechanical functionalization milling can combine base material 110 comprising a powder form with additive material 120 comprising a powder form via Attorney Docket No. ARC-001 -PCT mechanical mixing, vibrational mixing, or both. The mechanical functionalization milling can be configured to effectively homogenize the carbon nanomaterials into a metal matrix.

[0163]

[0144] In Fig. 3B, a variation of method 1000, method 1000b is shown. Fig. 3B illustrates a flow chart of an embodiment of method 1000, method 1000b, comprising STEP 1100, STEP 1200, and STEP 1300 for manufacturing the enhanced material, EM 100. Method 1000b can be performed using various processing approaches, as shown in Fig. 3B. As shown in STEP 1100, one or more source materials comprising base material 110 and / or additive material 120 are obtained. In this embodiment, the source materials comprise functionalized metal powder with carbon nanomaterials. The functionalized metal powder can comprise base material 110 (e.g., aluminum, copper, and / or other metal) that has been pre-combined with additive material 120 (e.g., the carbon nanomaterial). Additive material 120 can comprise one or more carbon nanomaterials such as graphene, carbon nanotubes, or both. Following STEP 1100, method 1000b proceeds to STEP 1200, whereby base material 110 and additive material 120 are processed to produce EM 100 and / or IM 100’. In this embodiment, STEP 1200 comprises primary raw material processing. For example, STEP 1200 can comprise one or more processing techniques selected to consolidate the functionalized metal powder into a bulk form. In some embodiments, STEP 1200 comprises directed energy deposition. The directed energy deposition can be performed using DED 219. DED 219 can comprise a directed energy deposition device configured to deposit the functionalized metal powder directly onto a surface while simultaneously melting the material.

[0164]

[0145] Alternatively, or additionally, STEP 1200 can comprise laser powder bed printing. The laser powder bed printing can be performed using a laser powder bed fusion device, such as LPBF 218. LB PF 218 can be configured to build base material 110 (e.g., aluminum, copper, and / or other metal) comprising metal in a layer-by-layer arrangement, with additive material 120 (e.g., the carbon nanomaterials) integrated throughout. In use, the functionalized metal powder can be spread in a thin layer over a build plate, and a laser can selectively melt areas of the powder based on a CAD model.

[0165]

[0146] Alternatively, or additionally, STEP 1200 can comprise powder sintering. The powder sintering can be performed using one or more furnaces, such as a first furnace 213 and / or a second furnace 217. The powder sintering process can comprise heating the functionalized metal powder to a temperature below the melting point of base material 110, such as to bond the Attorney Docket No. ARC-001 -PCT powder particles together while maintaining the distribution of additive material 120 throughout the material (e.g., EM 100 and / or IM 100’).

[0166]

[0147] Following STEP 1200, method 1000b can proceed to STEP 1300, whereby the additional processing of IM 100’ is performed. In this embodiment, STEP 1300 can comprise secondary material processing. STEP 1300 can comprise one or more processing techniques configured to shape and / or further process IM 100’ to produce EM 100 in a desired final form. In some embodiments, STEP 1300 can comprise wire drawing. The wire drawing can be performed using one or more wire drawing machines, such as WDM 216. WDM 216 can be configured to reduce the diameter of IM 100’ while maintaining the internal structure. In use, IM 100’ can be pulled through progressively smaller dies to produce a wire at a predetermined diameter.

[0167]

[0148] Alternatively, or additionally, STEP 1300 can comprise roll processing. The roll processing can be configured to shape IM 100’ into sheets, plates, and / or other arranged forms. The roll processing can be configured to maintain the distribution of additive material 120 within base material 110. The roll processing can be configured to produce a rolled form at a predetermined thickness and / or surface finish. In some embodiments, system 10 comprises a roll processing assembly, such as FE 299 comprising roll processing machinery and / or other wire forming components.

[0168]

[0149] Alternatively, or additionally, STEP 1300 can comprise forming. The forming can comprise one or more processes configured to shape IM 100’ into a final geometry. The forming can comprise one or more actions selected from the group consisting of: bending; stamping; extrusion; and combinations of these.

[0169]

[0150] In Fig. 3C, a variation of method 1000, method 1000c is shown. Fig. 3C illustrates a flow chart of an embodiment of method 1000, method 1000c, comprising STEP 1100, STEP 1200, and STEP 1300 for manufacturing the enhanced material, EM 100. As shown in STEP

[0170] 1100, one or more source materials comprising base material 110 and / or additive material 120 are obtained. In this embodiment, the source materials comprise a powder core wire comprising a carbon nanomaterial core. The powder core wire can comprise an outer metallic sheath and an inner core. Base material 110 can comprise the outer metallic sheath. Base material 110 can comprise one or more metals such as aluminum, copper, and / or other metal. Additive material 120 can comprise the inner core. Additive material 120 can comprise one or more carbon nanomaterials such as graphene, carbon nanotubes, or both. Following STEP 1100, method Attorney Docket No. ARC-001 -PCT

[0171] 1000c proceeds to STEP 1200, whereby base material 110 and / or additive material 120 are processed to produce EM 100 and / or IM 100’. In this embodiment, STEP 1200 comprises wire arc additive manufacturing. The wire arc additive manufacturing can be performed by one or more wire arc additive manufacturing devices, such as WAAM 221. WAAM 221 can be configured to use an electric arc to melt the powder core wire feedstock. In use, the powder core wire can be fed into the electric arc, where base material 110 (e.g., the outer metallic sheath) melts and the additive material 120 (e.g., carbon nanomaterial core) is dispersed and integrated throughout the molten metal. The wire arc additive manufacturing process can be configured to deposit the molten material layer by layer to build up IM 100’ in a desired shape.

[0172]

[0151] Following STEP 1200, method 1000c can proceed to STEP 1300, whereby additional processing of IM 100’ is performed. In this embodiment, STEP 1300 comprises secondary material processing. STEP 1300 can comprise one or more processing techniques configured to shape and / or further process IM 100’ to produce EM 100 in a desired final form. In some embodiments, STEP 1300 can comprise wire drawing. The wire drawing can be performed using WDM 216. The wire drawing can be configured to reduce the diameter of IM 100’ while maintaining the internal structure and the distribution of additive material 120 throughout base material 110. Alternatively, or additionally, STEP 1300 can comprise roll processing. The roll processing can be configured to shape IM 100’ into sheets, plates, and / or other arranged forms.

[0173] The roll processing can be configured to maintain the distribution of additive material 120 within base material 110. The roll processing can be configured to produce a rolled form at a predetermined thickness and / or surface finish. Alternatively, or additionally, STEP 1300 can comprise forming. The forming can comprise one or more processes configured to shape IM 100’ into a final geometry. The forming can comprise one or more actions selected from the group consisting of: bending; stamping; extrusion; and combinations of these.

[0174]

[0152] In Fig. 3D, a variation of method 1000, method lOOOd is shown. Figure 3D illustrates a flow chart of an embodiment of method 1000, method lOOOd, comprising STEP 1100, STEP 1200, and STEP 1300 for manufacturing the enhanced material, EM 100. Method lOOd can comprise one or more optional steps, such as STEP 1110 and STEP 1210, configured to enhance material properties during manufacturing. As shown in STEP 1100, one or more source materials comprising base material 110 and / or additive material 120 are obtained. In this embodiment, the source materials comprise a sintered or printed bar. The sintered or printed bar can comprise base Attorney Docket No. ARC-001 -PCT material 110 and / or additive material 120 that have been previously processed and / or consolidated. The sintered or printed bar can comprise one or more metals, such as aluminum, copper, and / or other metal with carbon nanomaterials integrated throughout the material.

[0175]

[0153] Following STEP 1100, method lOOOd can proceed to STEP 1200. Alternatively, or additionally, following STEP 1100, method lOOOd can proceed to STEP 1110. In some embodiments, STEP 1110 comprises hot isostatic press treatment (e.g., a hot isostatic press treatment applied by compactor 214). The hot isostatic press treatment can be configured to eliminate internal voids and improve material cohesion in the sintered or printed bar. In some embodiments, the hot isostatic press treatment is configured to apply high temperature and pressure simultaneously to densify the material and reduce density defects. Following STEP

[0176] 1100, method lOOOd proceeds to STEP 1200.

[0177]

[0154] In this embodiment, STEP 1200 comprises one or more primary raw material processing steps. For example, STEP 1200 can comprise STEP 1200a and STEP 1200b. In some embodiments, STEP 1200a comprises diameter reduction. The diameter reduction can comprise roll processing, drawing, or both. STEP 1200a can be configured to reduce the diameter of the sintered or printed bar while maintaining the distribution of additive material 120 within base material 110.

[0178]

[0155] Following STEP 1200a, method lOOOd can proceed to STEP 1200b. In some embodiments STEP 1200b comprises annealing. The annealing can comprise recrystallization and / or stress relief. The annealing can be configured to alter the microstructure of the material processed in STEP 1200a, such as to relieve internal stresses and / or enhance material properties. In some embodiments, annealing can be performed by second furnace 217, described herein.

[0179]

[0156] Following STEP 1200b, method lOOOd can return to STEP 1200a for additional diameter reduction processing. Alternatively, or additionally, following STEP 1200b, method lOOOd can proceed to STEP 1210. In some embodiments, STEP 1210 comprises hot isostatic press treatment. The hot isostatic press treatment of STEP 1210 can be configured to densify the material and eliminate any microfractures or defects that may have formed during the diameter reduction and / or annealing cycles. Following STEP 1210, method lOOOd proceeds to STEP 1300. Alternatively, or additionally, following STEP 1200b, method lOOOd can proceed directly to STEP 1300 without performing STEP 1210. Attorney Docket No. ARC-001 -PCT

[0180]

[0157] In STEP 1300, method lOOOd can perform additional processing of IM 100’. In this embodiment, STEP 1300 comprises secondary material processing. STEP 1300 can comprise one or more actions selected from the group consisting of: stranding; bundling; bending; winding; and combinations of these. The stranding can be configured to form multiple wires into a singular conductor configuration. The bundling can be configured to group multiple wires and / or strands together. The bending can be configured to shape IM 100’ into curved or angled configurations. The winding can be configured to coil IM 100’ into tight, precise conductor bundles.

[0181]

[0158] In Fig. 3E, a variation of method 1000, method lOOOe is shown. Fig. 3E illustrates a flow chart of an embodiment of method 1000, method lOOOe, comprising STEP 1100, STEP 1200, and STEP 1300 for manufacturing the enhanced material, EM 100. As shown in STEP

[0182] 1100, one or more source materials comprising base material 110 and / or additive material 120 are obtained. In this embodiment, base material 110 comprises atomized metal powders. For example, base material 110 can comprise one or more metals, such as aluminum, copper, and / or other metal. Additive material 120 can comprise one or more gas precursors. For example, additive material 120 can comprise hydrogen, methane, and / or other gas. The gas precursors can be configured to react during subsequent processing to form carbon-containing structures.

[0183]

[0159] Following STEP 1100, method lOOOe proceeds to STEP 1200, whereby base material 110 and additive material 120 are processed to produce EM 100 and / or IM 100’. In this embodiment, STEP 1200 comprises primary raw material processing. STEP 1200 can comprise one or more processing techniques configured to consolidate base material 110 (e.g., the atomized metal powders) while infusing additive material 120 (e.g., carbon nanomaterials) that is generated from the gas precursors. In some embodiments, STEP 1200 comprises directed energy deposition. The directed energy deposition can be performed using DED 219. During directed energy deposition, the atomized metal powders can be deposited and melted while the gas precursors are introduced into the deposition zone. The gas precursors can decompose under the high-temperature conditions created by the energy source to generate carbon nanomaterials that can integrate with the molten metal. The directed energy deposition process can enable in-situ carbon nanomaterial infusion during material fabrication.

[0184]

[0160] Alternatively, or additionally, STEP 1200 can comprise laser powder bed printing. The laser powder bed printing can be performed using LPBF 218. During laser powder bed Attorney Docket No. ARC-001 -PCT printing, the atomized metal powders (e.g., base material 110 and / or additive material 120) can be spread in a thin layer over a build plate, and a laser can selectively melt areas of the powder. Additive material 120 (e.g., gas precursors) can be introduced during the laser melting step. The gas precursors can create conditions for laser-assisted CVD, allowing carbon nanomaterials to form and bond with the molten metal.

[0185]

[0161] Following STEP 1200, method lOOOe can proceed to STEP 1300, whereby additional processing of IM 100’ is performed. In this embodiment, STEP 1300 can comprise secondary material processing. STEP 1300 can comprise one or more processing techniques configured to shape and / or further process IM 100’ to produce EM 100 in a desired final form. In some embodiments, STEP 1300 can comprise wire drawing. The wire drawing can be performed using WDM 216. The wire drawing can be configured to reduce the diameter of IM 100’ while maintaining the internal structure and the distribution of additive material 120 throughout base material 110. Alternatively, or additionally, STEP 1300 can comprise roll processing. The roll processing can be configured to shape IM 100’ into sheets, plates, and / or other arranged forms.

[0186] The roll processing can be configured to maintain the distribution of additive material 120 within base material 110. The roll processing can be configured to produce a rolled form at a predetermined thickness and / or surface finish. Alternatively, or additionally, STEP 1300 can comprise forming. The forming can comprise one or more processes configured to shape IM 100’ into a final geometry. The forming can comprise one or more actions selected from the group consisting of: bending; stamping; extrusion; and combinations of these.

[0187]

[0162] Referring to Fig. 4, a block diagram of a product comprising at least one device that includes an enhanced material is illustrated, consistent with the present inventive concepts. Product 300 comprises one or more assemblies, assembly 310, each as shown. Assembly 310 can comprise one or more components that include EM 100 as shown. In some embodiments, assembly 310 comprises one, two, or more assemblies, where different configurations of EM 100 are included (e.g., a first configuration EM 100a that has a first base material 110a and a first additive material 120a, and a second configuration EM 100b that has a second base material 110b and a second additive material 120b, wherein one or more of the EM 100 components are different). Product 300 can include additional components, additional components 320 shown. Attorney Docket No. ARC-001 -PCT

[0188]

[0163] Product 300 can comprise various types of products that take advantage of the enhanced properties of EM 100. In some embodiments, EM 100 is configured as an elongate conductor (e.g., a wire) and used in: power transmission lines; power grids; coils; motors; solenoids; electromagnetic actuators; electric vehicles; and / or any other conductor-including product or component. In some embodiments, EM 100 is configured as an elongate conductor and incorporated into a product 300 that comprises a medical device, for example a medical implant such as: a pacemaker; a defibrillator; a stimulator such as a pain-treating stimulator and / or a deep brain stimulator; and combinations of these. Medical device applications, in particular implanted devices, can significantly benefit from the enhanced materials of the present inventive concepts, for example as it relates to reduced energy requirements, reduced heating during use, and other advantages.

[0189]

[0164] Referring to Figs. 5A through 5C, three steps of a manufacturing process for producing an enhanced material are illustrated, consistent with the present inventive concepts. In Fig. 5A, a step in which a depositing process to create a wire is illustrated. Fig. 5A illustrates a deposition stage of a manufacturing process for producing enhanced material, EM 100. In some embodiments, the deposition stage can comprise an additive manufacturing process configured to deposit and solidify base material 110 (e.g., aluminum, copper, and / or other metal) along with additive material 120 (e.g., carbon nanomaterials). In some embodiments, the deposition stage can utilize a directed energy deposition process (e.g., 3D printing). In some embodiments, the deposition stage comprises a carrier gas. In some embodiments, the deposition stage comprises a shielding. In some embodiments, the deposition stage comprises a laser energy source configured to generate a melt pool within the deposited material. In some embodiments, the deposition stage is configured to produce a solidified wire comprising EM 100 and / or IM 100’. Fig. 5 A further illustrates representative scanning electron microscope (SEM) images at various stages of formation, SEM 1 and SEM 2 as shown. SEM 1 illustrates the distribution of additive material 120 particles prior to deposition (e.g., in the feedstock). SEM 2 illustrates the integrated structure of EM 100 and / or IM 100’ after solidification. Additive material 120 is shown to be uniformly distributed within base material 110.

[0190]

[0165] In Fig. 5B, a step in which carbon nanomaterials are aligned is illustrated. Fig. 5B illustrates a processing stage of the manufacturing process for producing EM 100. The Attorney Docket No. ARC-001 -PCT processing stage can comprise one or more mechanical treatment steps and / or one or more thermal treatment steps configured to modify one, two, or more properties of EM 100. The one or more mechanical treatment steps and / or the one or more thermal treatment steps can be configured to promote the alignment of additive material 120 (e.g., carbon nanomaterials) within a matrix of base material 110. The processing stage can be configured to re-orient additive material 120 (e.g., carbon nanomaterials) that comprises suboptimal orientation following the initial deposition stage. In some embodiments, the processing stage comprises a first drawing operation configured to reduce the cross-sectional dimension of EM 100, for example, passing EM 100 through one or more dies configured to progressively reduce the diameter. The drawing operation can be configured to apply plastic deformation and / or shear forces to EM 100. In some embodiments, the drawing operation promotes reorientation of additive material 120 along the longitudinal axis of EM 100. Additionally, or alternatively, the processing stage can comprise a heat treatment operation (e.g., an annealing operation). In some embodiments, the heat treatment operation is configured to occur between sequential drawing operations. The heat treatment operation can be configured to mitigate one or more work hardening effects, such as increased stiffness of EM 100, which can lead to reduced performance. Additionally, or alternatively, the processing stage can comprise a second drawing operation performed after the heat treatment operation. The second drawing operation can be configured to further reduce the cross-sectional dimension of EM 100. In some embodiments, the second drawing operation is configured to pass EM 100 through an additional die (e.g., nozzle) creating shear force conditions to promote further alignment of additive material 120. Fig. 5B further includes a magnified cross-sectional view of EM 100 during the processing stage. The magnified view illustrates alignment of additive material 120 along the longitudinal axis of EM 100.

[0191]

[0166] In Fig. 5C, a final output of EM 100 and an associated Raman spectrograph are illustrated. Fig. 5C illustrates a final wire comprising EM 100 and a corresponding Raman spectrograph characterization. In some embodiments, the final output of EM 100 (e.g., final wire) comprises a bundled configuration. In some embodiments, the final output of EM 100 comprises as a plurality of individual wires (e.g., EM 100 and / or IM 100’) bundled together to form a multi-conductor cable. The bundled configuration can be produced directly through additive manufacturing (e.g., printing a bundle of twisted conductors) or can be assembled after individual wires are produced. Fig. 5C also illustrates a magnification of the final product of EM Attorney Docket No. ARC-001 -PCT

[0192] 100, showing EM 100 infused with additive material 120 (e.g., carbon nanomaterials) evenly distributed throughout. In some embodiments, the final output of EM 100 undergoes one or more quality control checks, such as Raman spectroscopy. Fig. 5C illustrates a representation of a Raman spectrograph obtained from analysis of the final output of EM 100.

[0193]

[0167] Referring to Fig. 6, a graph of conductivity as a function of temperature for various materials is illustrated, consistent with the present inventive concepts. EM 100 can be configured as a conductor for use in power lines, electric motors, and other indications, and can have up to a 50% enhancement in conductivity. Fig. 6 includes a horizontal axis representing temperature in degrees Celsius (°C), ranging from approximately 20°C to approximately 240°C, and a vertical axis representing electrical conductivity in megasiemens per meter (MS / m). Fig. 6 illustrates conductivity data for multiple materials including: carbon nanomaterials (e.g., graphene, carbon nanotubes) as shown by a first curve (LI), EM 100 as shown by a second curve (L2), an early prototype EM 100 as shown by a third curve (L3), and a state-of-the-art (SOA) ‘3M Aluminum Matrix Core’ wire as shown by a fourth curve (L4). The carbon nanomaterials can exhibit a conductivity of approximately 100 MS / m across the entire temperature range. EM 100 can exhibit conductivity beginning at approximately 45 MS / m at approximately 20°C and can maintain a conductivity of approximately 35 MS / m at approximately 240°C. In some embodiments, EM 100 can exhibit approximately 50% enhanced conductivity relative to SOA aluminum wire across the same temperature range. In some embodiments, the SOA aluminum wire exhibits conductivity decreasing from approximately 38 MS / m at approximately 20°C to approximately 20 MS / m at approximately 240°C. Fig. 6 illustrates a target zone from approximately 140°C to 240°C of improvement of conductivity. The target zone can represent desired performance characteristics for EM 100

[0194]

[0168] Referring to Fig. 7, a graph of strength / density versus conductivity for various wire materials is illustrated, consistent with the present inventive concepts. The data presented in Fig. 7 demonstrates the sag reduction of EM 100. Note the ACSS wire shown is the industry standard. As shown in Fig. 7, EM 100 can eliminate the traditional tradeoff between conductivity and mechanical strength. In some embodiments, EM 100 comprises a single material with both high electrical conductivity and high mechanical strength. Fig. 7 includes a horizontal axis Attorney Docket No. ARC-001 -PCT representing strength divided by density in units of megapascals per cubic centimeter (MPa) / (g / cc), ranging from approximately 25 to approximately 250. Fig. 7 further includes a vertical axis representing electrical conductivity as a percentage of International Annealed Copper Standard (% IACS), ranging from approximately 0 to approximately 120. The graph illustrates performance data for multiple commercial conductor materials as well as a target performance region for EM 100. The graph shows various existing conductor materials including: cold drawn copper, cadmium copper, various alumni alloys, round and trapezoidal 3M ACCR configurations, and various ACS and ACCS industry standards. These existing materials can exhibit a fundamental tradeoff whereby materials with high conductivity (e.g., copper-based materials) can have relatively low specific strength, while materials with high specific strength (e.g., aluminum composite) can have relatively low conductivity. Fig. 7 illustrates a target area (shown as a shaded region with a dashed border) representing the performance distribution that can be achieved by EM 100. EM 100 can encompass conductivity values between approximately 70% IACS and approximately 100% IACS, combined with specific strength values between approximately 125 (MPa) / (g / cc) and approximately 200 (MPa) / (g / cc). EM 100 can be configured to exhibit a region of performance space not achieved by existing commercial conductor materials.

[0195]

[0169] The above-described embodiments should be understood to serve only as illustrative examples; further embodiments are envisaged. Any feature described herein in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the inventive concepts, which are defined in the accompanying claims.

Claims

Attorney Docket No. ARC-001 -PCTWHAT IS CLAIMED IS:

1. A manufacturing method for producing an enhanced material, comprising:(a) obtaining source materials comprising at least a base material and an additive material; and(b) processing at least the base material and the additive material to produce the enhanced material or an intermediate enhanced material.

2. The manufacturing method according to claim 1 and / or any other one or more claims herein, wherein step (b) is performed using the manufacturing system of any of claims 9 through 15.

3. The manufacturing method according to claim 1 and / or any other one or more claims herein, wherein the enhanced material comprises the enhanced material of any of claims 16 through 26.

4. The manufacturing method according to claim 1 and / or any other one or more claims herein, wherein the enhanced material is integrated into a product, and wherein the product comprises the product of any of claims 27 through 30.

5. The manufacturing method according to claim 1 and / or any other one or more claims herein, wherein the base material comprises: aluminum; copper; nickel; steel; and / or other metal, and wherein the additive material comprises carbon nanomaterial.

6. The manufacturing method according to claim 1 and / or any other one or more claims herein, wherein step (b) comprises a 3D printing process.

7. The manufacturing method according to claim 1 and / or any other one or more claims herein, wherein step (b) produces the intermediate enhanced material, and wherein the method further comprises:Attorney Docket No. ARC-001 -PCT(c) performing additional processing on the intermediate enhanced material to produce the enhanced material.

8. The manufacturing method according to claim 7 and / or any other one or more claims herein, wherein the additional processing comprises applying a cover to the intermediate enhanced material to encapsulate at least an additional material.

9. A manufacturing system for producing an enhanced material, the manufacturing system comprising: processing equipment configured to combine source materials comprising at least a base material and an additive material, wherein the manufacturing system is configured to produce the enhanced material comprising the source materials.

10. The manufacturing system of claim 9 and / or any other one or more claims herein, wherein the manufacturing system is configured to perform the method of any of claims 1 through 8.

11. The manufacturing system of claim 9 and / or any other one or more claims herein, wherein the manufacturing system is configured to produce the enhanced material of any of claims 16 through 26.

12. The manufacturing system of claim 9 and / or any other one or more claims herein, wherein the processing equipment comprises one or more pieces of equipment selected from the group consisting of: a mixer, such as a ball mill, a high-energy mixer, an ultrasonication device, and / or a bath sonication device; chemical vapor deposition system; a furnace, such as an induction furnace and / or a heat-treatment furnace; a compactor, such as a powder compactor and / or a cold isostatic press; an extruder, such as an extrusion press; a wire drawing machine; a laser powder bed fusion device; an additive printer; a 3D printer; a directed energy deposition device; aAttorney Docket No. ARC-001 -PCT diagnostic device; a wire arc additive manufacturing device; an atomizer, such as a powder gas atomizer; an additive printer; and combinations thereof.

13. The manufacturing system of claim 9 and / or any other one or more claims herein, further comprising a processing unit comprising a processor and a memory storage element coupled to the processor, wherein the memory storage element stores instructions for the processor to perform an algorithm.

14. The manufacturing system of claim 13 and / or any other one or more claims herein, wherein the algorithm comprises an Al algorithm.

15. The manufacturing system of claim 13 and / or any other one or more claims herein, wherein the algorithm is configured to adjust a process parameter, an equipment parameter, or both, in a closed-loop arrangement.

16. An enhanced material comprising: source materials comprising: a base material; and an additive material.

17. The enhanced material of claim 16 and / or any one or more other claims herein, wherein the enhanced material is produced using the manufacturing method of any of claims 1 through 8.

18. The enhanced material of claim 16 and / or any one or more other claims herein, wherein the enhanced material is produced using the manufacturing system of any of claims 9 through 15.

19. The enhanced material of claim 16 and / or any one or more other claims herein, wherein the enhanced material is integrated into the product of any of claims 27 through 30.Attorney Docket No. ARC-001 -PCT20. The enhanced material of claim 16 and / or any one or more other claims herein, wherein the base material comprises a metal.

21. The enhanced material of claim 20 and / or any one or more other claims herein, wherein the metal comprises a metal selected from the group consisting of: aluminum; copper; nickel; steel; and combinations thereof.

22. The enhanced material of claim 16 and / or any one or more other claims herein, wherein the enhanced material comprises material provided in the form of a filament.

23. The enhanced material of claim 16 and / or any one or more other claims herein, wherein the enhanced material comprises material provided in the form of an electrical conductor.

24. The enhanced material of claim 16 and / or any one or more other claims herein, wherein the additive material comprises a first additive material, and wherein the enhanced material further comprises a second additive material.

25. The enhanced material of claim 24 and / or any one or more other claims herein, wherein the second additive material is constructed and arranged as a cover that is positioned to prevent exposure of the first additive material to air.

26. The enhanced material of claim 24 and / or any one or more other claims herein, wherein the second additive material comprises a metal, a non-metal, or both.

27. A product including an enhanced material, wherein the product comprises the enhanced material of any of claims 16 through 26.

28. The product according to claim 27 and / or any one or more other claims herein, wherein the product comprises a product selected from the group consisting of: power transmission lines; power grids; coils; motors; solenoids; electromagnetic actuators; electric vehicles; any conductor-including product or component; and combinations thereof.Attorney Docket No. ARC-001 -PCT29. The product according to claim 27 and / or any one or more other claims herein, wherein the product comprises a medical device.

30. The product according to claim 29 and / or any one or more other claims herein, wherein the medical device comprises an implanted device, such as an implanted device selected from the group consisting of: a pacemaker; a defibrillator; a stimulator, such as a pain-treating stimulator and / or a deep brain stimulator; and combinations thereof.

31. A manufacturing method for producing an enhanced material, a manufacturing system for producing an enhanced material, an enhanced material, and / or a product including an enhanced material, as described in reference to the drawings.

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