Multi-material braided feedstock system for additive manufacturing

Abstract

A system for creating multi-material feedstock for additive manufacturing includes a hollow stepper motor, a linear axis motor on which the hollow stepper motor is mounted, a braiding coupler attached to the hollow stepper motor, the braiding coupler configured to accommodate multiple wire filaments, an extruder module, and a controller configured to operate the hollow stepper motor and the extruder module simultaneously to twist and braid the multiple wire filaments into a single braided feedstock. The extruder module is configured to drive the single braided feedstock from the braiding coupler to a build platform.

Description

Atty. Docket No.: 208192-0030-WO01MULTI-MATERIAL BRAIDED FEEDSTOCK SYSTEM FOR ADDITIVE MANUFACTURINGCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 727,392, filed December 3, 2024, which is hereby incorporated by reference in its entirety.FIELD OF INVENTION

[0002] The present disclosure relates to additive manufacturing systems and methods, and more particularly to a metal multi-material braiding system and method for resonant- assisted deposition in additive manufacturing processes, such as solid-state additive manufacturing processes.BACKGROUND

[0003] Additive manufacturing has revolutionized the way complex parts and structures are produced across various industries. This technology enables the creation of intricate geometries and customized components that were previously difficult or impossible to manufacture usingtraditional methods. As the field has advanced, there has been a growing demand for additive manufacturing processes capable of incorporating multiple materials within a single part to achieve enhanced functionality and performance.

[0004] Metal additive manufacturing, in particular, has gained significant attention due to its potential to produce high-strength, lightweight parts for aerospace, automotive, and medical applications. However, integrating multiple materials in metal additive manufacturing processes presents unique challenges. These challenges include managing different material properties, ensuring proper bonding between dissimilar metals, and maintaining dimensional accuracy throughout the build process.

[0005] Existing approaches to multi-material metal additive manufacturing often involve complex hardware setups, such as multiple extruders or powder feed systems. These solutions can increase manufacturing time, system complexity, and overall costs.Atty. Docket No.: 208192-0030-WO01Additionally, the computational requirements for processing and controlling multi-material builds can be substantial, potentially limitingthe scalability and efficiency of such systems.SUMMARY

[0006] Solid-state additive manufacturing techniques, which do not rely on melting the feedstock material address some of the challenges associated with multi-material metal printing. These methods can reduce thermal stresses, minimize material property changes, and allow for the combination of materials that are difficult to join using traditional fusionbased processes. The present disclosure identifies improved systems and methods that efficiently integrate multiple metal materials into a single additive manufacturing process without significantly increasing complexity or sacrificing production speed. Such innovations expand the capabilities of metal additive manufacturing and enable the creation of parts with tailored properties and functionalities that are not achievable with current technologies.

[0007] In some aspects, the techniques described herein relate to a solid-state additive manufacturing apparatus, including: a braiding system configured to create a multi-material braided feedstock from multiple wire filaments; and a deposition system configured to receive the multi-material braided feedstock and deposit it using a resonant-assisted deposition technique to form a three-dimensional object.

[0008] In some aspects, the techniques described herein relate to a solid-state additive manufacturing apparatus, wherein the braiding system includes: a hollow stepper motor; a linear axis motor on which the hollow stepper motor is mounted; a braiding coupler attached to the hollow stepper motor, the braiding coupler configured to accommodate the multiple wire filaments; an extruder module configured to drive the braided wire from the braiding coupler to the deposition system; and a controller configured to operate the hollow stepper motor and the extruder module simultaneously to twist and braid the multiple wire filaments into the multi-material braided feedstock.

[0009] In some aspects, the techniques described herein relate to a solid-state additive manufacturing apparatus, wherein the controller is configured to create at least one of a Z-Atty. Docket No.: 208192-003 O-WOOl twist braid pattern, an S-twist braid pattern, or a coaxial braid pattern usingthe multiple wire filaments.

[0010] In some aspects, the techniques described herein relate to a solid-state additive manufacturing apparatus, wherein the controller is further configured to adjust a pitch of the multi-material braided feedstock by varying a number of rotations of the hollow stepper motor relative to a linear axis length.

[0011] In some aspects, the techniques described herein relate to a solid-state additive manufacturing apparatus, wherein the deposition system includes a capillary tool with an inner diameter larger than a diameter of the multi-material braided feedstock.

[0012] In some aspects, the techniques described herein relate to a solid-state additive manufacturing apparatus, wherein the resonant-assisted deposition technique operates at frequencies between 5 kHz and 180 kHz and employs amplitudes between 0.5 and 2 micrometers.

[0013] In some aspects, the techniques described herein relate to a system for creating multi-material feedstock for additive manufacturing, including: a hollow stepper motor; a linear axis motor on which the hollow stepper motor is mounted; a braiding coupler attached to the hollow stepper motor, the braiding coupler configured to accommodate multiple wire filaments; an extruder module; and a controller configured to operate the hollow stepper motor and the extruder module simultaneously to twist and braid the multiple wire filaments into a single braided feedstock, wherein the extruder module is configured to drive the single braided feedstock from the braiding coupler to a build platform.

[0014] In some aspects, the techniques described herein relate to a system, wherein the braiding coupler is configured to accommodate at least two wire filaments of different materials.

[0015] In some aspects, the techniques described herein relate to a system, wherein the controller is further configured to adjust a pitch of the braided feedstock by varying a number of rotations of the hollow stepper motor relative to a linear axis length.Atty. Docket No.: 208192-0030-W001

[0016] In some aspects, the techniques described herein relate to a system, wherein the controller is configured to create a Z-twist or S-twist braid pattern using two wire filaments.

[0017] In some aspects, the techniques described herein relate to a system, wherein the controller is configured to create a coaxial braid pattern using two or more wire filaments.

[0018] In some aspects, the techniques described herein relate to a system, wherein the coaxial braid pattern includes a central wire filament and one or more outer wire filaments twisted around the central wire filament.

[0019] In some aspects, the techniques described herein relate to a system, wherein the controller is further configured to adjust a pitch of the one or more outer wire filaments relative to the central wire filament.

[0020] In some aspects, the techniques described herein relate to a method for creating multi-material feedstock for solid-state additive manufacturing, including: securing multiple wire filaments in a braiding coupler attached to a hollow stepper motor, the hollow stepper motor mounted on a linear axis motor; simultaneously activating the hollow stepper motor and the linear axis motor to twist and braid the multiple wire filaments; forming a single braided feedstock from the twisted and braided multiple wire filaments; and driving the single braided feedstock towards a deposition system and build platform.

[0021] In some aspects, the techniques described herein relate to a method, wherein the multiple wire filaments include at least two wire filaments of different materials.

[0022] In some aspects, the techniques described herein relate to a method, further including adjusting a pitch of the braided feedstock by varying a number of rotations of the hollow stepper motor relative to a linear axis length.

[0023] In some aspects, the techniques described herein relate to a method, wherein forming the single braided feedstock includes creating a Z-twist or S-twist braid pattern usingtwo wire filaments.Atty. Docket No.: 208192-0030-WO01

[0024] In some aspects, the techniques described herein relate to a method, wherein forming the single braided feedstock includes creating a coaxial braid pattern using two or more wire filaments.

[0025] In some aspects, the techniques described herein relate to a method, wherein the coaxial braid pattern includes a central wire filament and two outer wire filaments twisted around the central wire filament.

[0026] In some aspects, the techniques described herein relate to a method, further including adjusting a pitch of the two outer wire filaments relative to the central wire filament.

[0027] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.BRIEF DESCRIPTION OF FIGURES

[0028] Non-limiting and non-exhaustive examples are described with reference to the following figures.

[0029] FIG. 1A illustrates a first feedstock formed as an arrangement of wires and a resultant build layers, in accordance with some embodiments.

[0030] FIG. 1 B illustrates a second feedstock formed as an arrangement of wires and a resultant build layers, in accordance with other embodiments.

[0031] FIG. 2 is a perspective view of an end-effector having a resonance-assisted deposition apparatus for forming and depositing feedstocks such as those shown in FIGS. 1A and 1 B.

[0032] FIG. 3 is a front view of the resonance-assisted deposition apparatus of FIG. 2.

[0033] FIG. 4A is a front view of the end-effector of FIG. 2 forming a feedstock having three wires.

[0034] FIG. 4B is an enlarged view of the feedstock formed in FIG. 4A.Atty. Docket No.: 208192-0030-WO01

[0035] FIG. 5B is a front view of the end-effector of FIG. 2 forming a feedstock having two wires.

[0036] FIG. 5B is an enlarged view of the feedstock formed in FIG. 5A.DETAILED DESCRIPTION

[0037] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.

[0038] The present disclosure relates to a system and method for creating multimaterial feedstock for solid-state additive manufacturing. FIGS 2-4A and 5A illustrate a resonance-assisted deposition apparatus (i.e., braiding system) (FIG. 3) formed as a portion of an end-effector 115 (i.e., additive manufacturing apparatus) and a feedstock 100 (inclusive of feedstocks 100A, 100B, 100C). In some embodiments, the resonance-assisted deposition apparatus may be decoupled from the end-effector 115 and used separately (e.g., to make braided feedstock 100 for other systems) The feedstock 100 is composed of multiple (e.g., at least two, two, three, four, five, etc.) strands of fine-wire or filament of similar or dissimilar material and / or diameters. The system includes a solid-state additive manufacturing apparatus. The solid-state additive manufacturing apparatus may include a braiding system for creating multi-material braided feedstock from multiple wire filaments. The braiding system may be configured to combine and twist multiple wire filaments into a single "super-structured" feedstock. The solid-state additive manufacturing apparatus includes a deposition system. The deposition system is configured to receive the multimaterial braided feedstock created by the braiding system. In some cases, the deposition system may deposit the multi-material braided feedstock using a resonant-assisted deposition technique to form a three-dimensional object. In some embodiments, the braiding system is incorporated into the additive manufacturing apparatus (i.e., the apparatus with a deposition tool 130 for depositing the material onto a build platform 120). In other embodiments, the braiding system is separate from the additive manufacturingAtty. Docket No.: 208192-0030-WO01 apparatus. FIGS. 1 A-1 B illustrate two additional arrangements of wires and their resultant build layers. These figures demonstrate how the multi-material braided feedstock may be deposited to create complex three-dimensional structures with varying material properties.

[0039] The feedstock 100 is composed of multiple strands of fine-wire or filament. In some cases, these strands may be of similar material and diameter. In other cases, the strands may be of dissimilar materials and / or diameters. This flexibility in feedstock composition allows for the creation of customized material properties in the final three- dimensional object. The resonance-assisted deposition apparatus 115 utilizes the multimaterial braided feedstock to build three-dimensional objects layer by layer. By using feedstock composed of multiple materials, the resonance-assisted deposition apparatus 115 may create objects with complex material properties that may not be achievable with single-material feedstock. The resonance-assisted deposition apparatus 115 is configured to receive and process the feedstock 100. In some cases, the feedstock 100 may comprise a first wire 105 and a second wire 110. The first wire 105 and the second wire 110 may be of similar or dissimilar materials and / or diameters. The feedstock 100 may be created by braiding or twisting the first wire 105 and the second wire 110 together to form a multimaterial braided configuration.

[0040] In some cases, the resonance-assisted deposition apparatus 115 may include a deposition system. The deposition system may comprise a capillary tool. The capillary tool may have an inner diameter larger than a diameter of the feedstock 100. This configuration may allow the feedstock 100 to be fed smoothly through the capillary tool during the deposition process.

[0041] The resonance-assisted deposition apparatus 115 may operate using a resonant-assisted deposition technique. In some cases, the resonant-assisted deposition technique may operate at frequencies between 5 kHz and 180 kHz. This frequency range allows for precise control over the deposition process, enabling the creation of complex three-dimensional structures with varying material properties. The resonance-assisted deposition apparatus 115 employs vibrations to facilitate the deformation and bonding of materials during deposition. In some cases, the vibrations may have amplitudes betweenAtty. Docket No.: 208192-0030-WO010.5 and 2 micrometers. The frequency and amplitude of these vibrations may be adjusted based on various factors, such as material properties, deposition velocity, and the specific multi-material braided configuration of the feedstock 100. By utilizing the multi-material braided feedstock 100, the resonance-assisted deposition apparatus 115 enables the production of additively manufactured metal products with physical, mechanical, thermal, electrical, and chemical properties that may not be available in monolithic materials. This approach may provide a simple and cost-effective way of introducing multiple materials into a metal additive manufacturing process without increasing computational complexity or hindering production speed.

[0042] FIGS. 1A-1 B illustrate two arrangements of wires and their resultant build layers. The feedstock 100 is deposited onto a build platform 120 using a deposition tool 130 to form a resultant build layer 140. In some embodiments, the deposition tool 130 may include a capillary tool with an inner diameter larger than the diameter of the feedstock 100. This configuration may allow the feedstock 100 to be fed smoothly through the deposition tool 130 while the resonant-assisted deposition process is applied. The arrangement of the first wire 105 and the second wire 110 within the feedstock 100 influence the properties and structure of the resultant build layer 140. The feedstock 100 maybe configured with different braiding patterns or wire arrangements. These arrangements may include various combinations of the first wire 105 and the second wire 110 (and an additional third wire, fourth wire, fifth wire, etc., not shown), such as Z-twist, S-twist, or coaxial braids. The specific arrangement of wires within the feedstock 100 affect the characteristics of the resultant build layer 140.

[0043] The resultant build layer 140 has a controlled porosity. In some cases, controlled porosity may be achieved by selectively etching one material from the printed structure. For example, if the first wire 105 and the second wire 110 are made of different materials, one material may be selectively removed after the deposition process, creating a porous structure within the resultant build layer 140. The resultant build layer 140 may include integrated authentication patterns and taxonomy. In some cases, these patterns may be created by adjusting the pitch and patterns of the braided configurations of the first wire 105Atty. Docket No.: 208192-0030-WO01 and the second wire 110 within the feedstock 100. Subsequently, one material may be etched, revealing the embedded patterns within the resultant build layer 140. This feature allows for the creation of unique identifiers or authentication markers directly within the printed structure.

[0044] The resonance-assisted deposition apparatus 115 deposits the feedstock 100 in various patterns or configurations to achieve specific properties in the resultant build layer 1 0. By manipulating the arrangement of the first wire 105 and the second wire 110 within the feedstock 100, and controlling the deposition process, the resonance-assisted deposition apparatus 115 may create complex structures with tailored mechanical, thermal, or electrical properties.

[0045] The system for creating multi-material feedstock for solid-state additive manufacturing includes components that enable different braiding configurations. For example, the system may include a hollow stepper motor mounted on a linear axis motor. A braiding coupler may be attached to the hollow stepper motor, and the braiding coupler may be configured to accommodate multiple wire filaments. The system also includes a controller configured to operate the hollow stepper motor and the linear axis motor simultaneously. This simultaneous operation allows the system to twist and braid the multiple wire filaments into a single braided feedstock. The controller is capable of creating various braiding patterns using the multiple wire filaments. In some cases, the controller may be configured to create a Z-twist braid pattern. The Z-twist pattern may be achieved (e.g., by twisting two wire filaments in a clockwise direction.) In other cases, the controller may create an S-twist braid pattern (e.g., by twisting two wire filaments in a counterclockwise direction). Additionally, the controller may be configured to create a coaxial braid pattern using three wire filaments. In some cases, the coaxial braid pattern may comprise a central wire filament and one or more (e.g., two) outer wire filaments twisted around the central wire filament, as shown in Fig. 1 B. This configuration allows for the creation of feedstock with a core material surrounded by one or more different materials.Atty. Docket No.: 208192-0030-WO01

[0046] The method for creating multi-material feedstock includes securing multiple wire filaments in a braiding coupler attached to the hollow stepper motor. The hollow stepper motor is mounted on the linear axis motor. The hollow stepper motor and the linear axis motor are simultaneously activated to twist and braid the multiple wire filaments. This process results in forming a single braided feedstock from the twisted and braided multiple wire filaments. In some cases, the multiple wire filaments include at least two (e.g., two, three, four, five, etc.) wire filaments of different materials. This configuration allows for the creation of feedstock with varying material properties throughout its cross-section.

[0047] FIGS. 1A-1 B illustrate two arrangements of wires and their resultant build layers. The feedstock 100 may be configured with different braided patterns or wire arrangements. By utilizing different braiding configurations, the system creates feedstock with varied properties. FIG. 1A illustrates two wires 105, 110 braided about one another. FIG. 1 B illustrates a first wire 105 coiled around a second wire 110. The ability to create different braiding patterns allows for customization of material properties within a single printed structure, enhancing the versatility and functionality of the final product.

[0048] The resonance-assisted deposition apparatus 115 utilizes a resonant-assisted deposition process to deposit the feedstock 100 and create three-dimensional objects. In some cases, the resonant-assisted deposition process operates at frequencies between 5 kHz and 180 kHz with amplitudes between 0.5 and 2 micrometers to facilitate the deformation and bonding of materials during deposition. The frequency and amplitude of the vibrations used in the resonant-assisted deposition process may be adjusted based on various factors. These factors may include the material properties of the feedstock 100, the deposition velocity, and the specific multi-material braided configuration of the feedstock 100. By adjustingthese parameters, the resonance-assisted deposition apparatus 115 may achieve precise control over the deposition process. In some cases, the resonant-assisted deposition process may enable the resonance-assisted deposition apparatus 115 to deposit the feedstock 100 in a manner that preserves the multi-material structure of the feedstock 100. The first wire 105 and the second wire 110 within the feedstock 100 may maintain their relative positions during deposition, allowing for the creation of complexAtty. Docket No.: 208192-0030-WO01 structures with varying material properties. The resonant-assisted deposition process may also facilitate the deformation of the feedstock 100 as the feedstock 100 is deposited onto the build platform 120. The vibrations applied by the resonance-assisted deposition apparatus 115 may cause localized softening of the materials in the feedstock 100, allowing for improved bonding between layers of deposited material.

[0049] The multi-material braided feedstock system also offers advantages in terms of manufacturing efficiency and material utilization. By combining multiple materials into a single feedstock 100, the system reduces the need for multiple deposition tools or material changes during the manufacturing process. This efficiency leads to reduced production times and improved cost-effectiveness in additive manufacturing applications.

[0050] Referring to FIG. 2, an end effector 115 having a resonance-assisted deposition apparatus includes several structural components in the illustrated embodiment. A frame 145 provides the primary structural support for the apparatus. A panel bracket 147 of the frame 145 supports the components (e.g., extruder module 170) of the resonance-assisted deposition apparatus and an E-bracket 146 of the frame 145 couples the panel bracket 147 to a back bracket 149. A coupler 148 connects different sections of the frame 145 together and functions as a mounting point for the hollow stepper motor 155. The back bracket 149 enables attachment of the end-effector 115 to a linear axis, which drives the end-effector 115 up and down to apply static compression in a braided wire. A modular bracket 150 provides additional structural support forthe deposition tool 130 and transducer 190.

[0051] The two wires 105, 110 are coupled to the frame 145 on spools positioned between the two vertical panel brackets 147. The end-effector 115 includes a hollow stepper motor 155 with a feedstock inlet 155Athat allows entry of a third wire 112 (Figs. 4A- 4B) into the system.

[0052] As shown in FIG. 3, the resonance-assisted deposition apparatus includes a hollow stepper motor 155 with a feedstock inlet 155A through which the third wire 112Atty. Docket No.: 208192-0030-WO01 filament may enter the braiding system. A braiding coupler 160 (FIG. 2) attaches to the hollow stepper motor 155 and accommodates the multiple wire filaments 105, 110, 112. The braiding coupler 160 includes a feedstock outlet 165 through which the braided wire exits after processing via the coupler 160.

[0053] An extruder module 170 drives the braided feedstock 100 and maintains a controlled pitch configuration of the feedstock 100. The extruder module 170 includes a pair of rollers 175 that engage with the feedstock 100 to provide driving force. The extruder module 170 operates independently of z-axis motion, allowing the system to maintain consistent feedstock delivery regardless of vertical movement of the end-effector. The resonance-assisted deposition apparatus (including the motor 155, the braiding coupler 160 and the extruder module 170) can be decoupled from the end-effector for separate operation.

[0054] The system includes a deposition tool 130 that receives the multi-material braided feedstock and deposits the material onto a build platform 120. The deposition tool 130 forms part of a deposition system that uses a resonant-assisted deposition technique. The deposition tool 130 comprises a capillary tool with an inner diameter larger than a diameter of the multi-material braided feedstock 100, allowing smooth passage of the feedstock 100 through the tool.

[0055] The transducer 190 generates acoustic shear stress in the wire for solid-state consolidation. The transducer 190 creates vibrations that facilitate the deformation and bonding of materials during the deposition process. The resonant-assisted deposition technique operates at frequencies between 5 kHz and 180 kHz and employs amplitudes between 0.5 and 2 micrometers, though the system is not limited to these ranges. The technique creates vibrations that facilitate material deformation and bonding during deposition to form a three-dimensional object. A resultant build layer 140 forms on the build platform 120 as the feedstock 100 is deposited.Atty. Docket No.: 208192-0030-WO01

[0056] The braiding system can be decoupled from the end-effector and used separately for making braided configured feedstock for other systems. This configuration allows the apparatus to function as a standalone feedstock preparation system when the braiding components are separated from the deposition components.

[0057] Referring to FIGS. 4A-4B, the end-effector 115 operates to create feedstock 100C using three wire filaments in a coaxial braid pattern. A third wire filament enters the braiding system through feedstock inlet 155A of hollow stepper motor 155, while the first wire 105 and the second wire 110 are provided from wire spools positioned on the frame 145 form the outer wire filaments. The hollow stepper motor 155 rotates the braiding coupler 160 to twist the first wire 105 and second wire 110 around the central third wire filament that passes through the feedstock inlet 155A.

[0058] The controller operates the hollow stepper motor 155 to create the coaxial braid pattern with the central wire filament and two outer wire filaments twisted around the central wire filament. The controller adjusts a pitch of the braided feedstock 100C by varying a number of rotations of the hollow stepper motor 155 relative to a linear axis length. The controller further adjusts a pitch of the one or more outer wire filaments relative to the central wire filament by controlling the rotational speed and timing of the hollow stepper motor 155.

[0059] As shown in FIG. 4B, the resulting feedstock 100C displays the coaxial braid configuration with the central wire 112 surrounded by the two outer wires 105, 110 in a helical pattern. The feedstock 100C comprises multiple strands of fine-wire or filament of similar or dissimilar material and diameters, allowing for customized material properties throughout the cross-section of the braided feedstock 100C. The method for creating multimaterial feedstock includes forming a single braided feedstock 100C by creating a coaxial braid pattern usingtwo or more wire filaments, where the coaxial braid pattern comprises aAtty. Docket No.: 208192-0030-W001 central wire filament 112 and two outer wire filaments 100, 105 twisted around the central wire filament.

[0060] Referring to FIGS. 5A-5B, the end-effector 115 operates to create feedstock 100A using two wire filaments in a Z-twist or S-twist braid pattern. The first wire 105 and the second wire 110 are provided from wire spools positioned on the frame 1 5, with no third wire filament entering through the feedstock inlet 155A of the hollow stepper motor 155. The braiding coupler 160 accommodates the two wire filaments of different materials, securing the first wire 105 and second wire 110 for the braiding process.

[0061] The controller operates the hollow stepper motor 155 and the extruder module 170 simultaneously to twist and braid the two wire filaments. The controller creates a Z-twist braid pattern by rotating the hollow stepper motor 155 in a clockwise direction, or creates an S-twist braid pattern by rotating the hollow stepper motor 155 in a counterclockwise direction. The hollow stepper motor 155 rotates the braiding coupler 160 to twist the first wire 105 and second wire 110 together without a central wire filament.

[0062] The method for creating multi-material feedstock includes securing the multiple wire filaments in the braiding coupler 160 attached to the hollow stepper motor 155, where the hollow stepper motor 155 is mounted on a linear axis motor. The controller adjusts a pitch of the braided feedstock 100A by varying a number of rotations of the hollow stepper motor 155 relative to a linear axis length. The system forms a single braided feedstock 100A from the twisted and braided multiple wire filaments comprising at least two wire filaments of different materials.

[0063] As shown in FIG. 5B, the resulting feedstock 100A displays the two-wire braid configuration with the first wire 105 and second wire 110 twisted together in the selected braid pattern. The feedstock 100A comprises multiple strands of fine-wire or filament of similar or dissimilar materials and diameters, allowing for customized material properties throughout the cross-section of the braided feedstock 100A.Atty. Docket No.: 208192-0030-W001

[0064] The resultant build layer formed from feedstock 100A has controlled porosity achieved by selectively etching one material from the printed structure. When the first wire 105 and second wire 110 comprise different materials, one material can be selectively removed afterthe deposition process, creating a porous structure within the resultant build layer. The resultant build layer includes integrated authentication patterns and taxonomy created by adjusting the pitch and patterns of the braided configurations of the first wire 105 and second wire 110 within the feedstock 100A, with one material subsequently etched to reveal embedded patterns within the resultant build layer.

[0065] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Claims

Atty. Docket No.: 208192-003 O-WOOlCLAIMS1 . A solid-state additive manufacturing apparatus, comprising: a braiding system configured to create a multi-material braided feedstock from multiple wire filaments; and a deposition system configured to receive the multi-material braided feedstock and deposit it using a resonant-assisted deposition technique to form a three-dimensional object.

2. The solid-state additive manufacturing apparatus of claim 1 , wherein the braiding system comprises: a hollow stepper motor; a linear axis motor on which the hollow stepper motor is mounted; a braiding coupler attached to the hollow stepper motor, the braiding coupler configured to accommodate the multiple wire filaments; an extruder module configured to drive the braided wire from the braiding coupler to the deposition system; and a controller configured to operate the hollow stepper motor and the extruder module simultaneously to twist and braid the multiple wire filaments into the multi-material braided feedstock.

3. The solid-state additive manufacturing apparatus of claim 2, wherein the controller is configured to create at least one of a Z-twist braid pattern, an S-twist braid pattern, or a coaxial braid pattern using the multiple wire filaments.

4. The solid-state additive manufacturing apparatus of claim 3, wherein the controller is further configured to adjust a pitch of the multi-material braided feedstock by varying a number of rotations of the hollow stepper motor relative to a linear axis length.Atty. Docket No.: 208192-003 O-WOOl5. The solid-state additive manufacturing apparatus of claim 1 , wherein the deposition system comprises a capillary tool with an inner diameter larger than a diameter of the multimaterial braided feedstock.

6. The solid-state additive manufacturing apparatus of claim 5, wherein the resonant- assisted deposition technique operates at frequencies between 5 kHz and 180 kHz and employs amplitudes between 0.5 and 2 micrometers.

7. A system for creating multi-material feedstock for additive manufacturing, comprising: a hollow stepper motor; a linear axis motor on which the hollow stepper motor is mounted; a braiding coupler attached to the hollow stepper motor, the braiding coupler configured to accommodate multiple wire filaments; an extruder module; and a controller configured to operate the hollow stepper motor and the extruder module simultaneouslyto twist and braid the multiple wire filaments into a single braided feedstock, wherein the extruder module is configured to drive the single braided feedstock from the braiding coupler to a build platform.

8. The system of claim 7, wherein the braiding coupler is configured to accommodate at least two wire filaments of different materials.

9. The system of claim 8, wherein the controller is further configured to adjust a pitch of the braided feedstock by varying a number of rotations of the hollow stepper motor relative to a linear axis length.

10. The system of claim 7, wherein the controller is configured to create a Z-twist or S-twist braid pattern usingtwo wire filaments.Atty. Docket No.: 208192-003 O-WOOl1 1. The system of claim 7, wherein the controller is configured to create a coaxial braid pattern using two or more wire filaments.

12. The system of claim 11 , wherein the coaxial braid pattern comprises a central wire filament and one or more outer wire filaments twisted around the central wire filament.

13. The system of claim 12, wherein the controller is further configured to adjust a pitch of the one or more outer wire filaments relative to the central wire filament.1 . A method for creating multi-material feedstock for solid-state additive manufacturing, comprising: securing multiple wire filaments in a braiding coupler attached to a hollow stepper motor, the hollow stepper motor mounted on a linear axis motor; simultaneously activating the hollow stepper motor and the linear axis motor to twist and braid the multiple wire filaments; forming a single braided feedstock from the twisted and braided multiple wire filaments; and drivingthe single braided feedstock towards a deposition system and build platform.

15. The method of claim 14, wherein the multiple wire filaments comprise at least two wire filaments of different materials.

16. The method of claim 15, further comprising adjusting a pitch of the braided feedstock by varying a number of rotations of the hollow stepper motor relative to a linear axis length.

17. The method of claim 14, wherein forming the single braided feedstock comprises creating a Z-twist or S-twist braid pattern using two wire filaments.Atty. Docket No.: 208192-003 O-WOOl18. The method of claim 14, wherein forming the single braided feedstock comprises creating a coaxial braid pattern using two or more wire filaments.

19. The method of claim 18, wherein the coaxial braid pattern comprises a central wire filament and two outer wire filaments twisted around the central wire filament.

20. The method of claim 19, further comprising adjusting a pitch of the two outer wire filaments relative to the central wire filament.

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