Continuous feed spindle attachment

A rotating tool system attachment on the spindle of a computer numerical control (“CNC”) machine includes a rotating assembly mounted on a static assembly. The rotating assembly provides a continuous supply of a wire material for deposition on a substrate during an additive manufacturing process. The rotating assembly includes a material supply housing a feedstock of wire mounted on a rotating spindle and a wire feeder configured to draw the wire from the wire supply and provide the wire for application during the additive manufacturing process. The tool system can be attached to the spindle of CNC machine to provide additive manufacturing capabilities to the CNC machine.

BACKGROUND

This disclosure relates generally to additive manufacturing. More specifically, this disclosure relates to a tool system that can be attached to the spindle of a milling machine that can be utilized in additive manufacturing.

Additive manufacturing is a process whereby components are manufactured in a layer-by-layer fashion. Additive manufacturing allows complex design features to be incorporated into parts where those complex design features were infeasible with previous manufacturing techniques. One form of additive manufacturing, referred to as solid state additive manufacturing (“SSAM”), involves applying a deposition material to a substrate without requiring the deposition material to undergo a phase change. In friction surfacing additive manufacturing (“FSAM”), which is a form of SSAM, friction and pressure between the deposition material and the substrate cause the deposition material to heat to near its melting point, thereby causing the deposition material to plasticize but not melt. The plasticized deposition material is then applied to the substrate. The layers of deposition material can be machined into a final form.

Computer numerical control (“CNC”) machines are automated machine tools controlled by computers that execute pre-programmed sequences of control commands to have the machine tools shape a workpiece. CNC machines remove material from the workpiece, such as through grinding or milling, to shape the workpiece into the final form. CNC machines can include a machine spindle that can attach to various tool attachments to machine the workpiece. The computer is pre-programmed with instructions, and the computer controls the machine spindle and the tool attachment to shape the workpiece. The machine spindle can utilize multiple tool attachments to machine a single workpiece into the final form. The machine spindle can automatically change between multiple tool attachments as the workpiece is shaped.

SUMMARY

According to one aspect of the disclosure, a spindle attachment includes a static assembly and a rotating assembly mounted on and extending through the static assembly. The rotating assembly includes a spindle having an upper end and an application tip, wherein the spindle extends through the static assembly and the application tip projects out of a lower end of the static assembly, the spindle configured to rotate on a spindle axis relative to the static assembly, a material supply mounted on the spindle, and a wire feeder disposed within the spindle, the wire feeder configured to engage a wire extending from the material supply and to draw the wire from the material supply and through the spindle. The wire feeder is configured to provide a continuous supply of wire from the material supply to the application tip during an additive manufacturing process.

According to another aspect of the disclosure, a computer numerical control machine includes a work area configured to house a workpiece to be shaped into a final configuration, a plurality of spindle attachments configured to shape the workpiece, a machine spindle configured to attach to and manipulate a position and rotation of the plurality of spindle attachments, and a controller communicatively connected to the machine spindle, the controller configured to receive and store the final configuration in a memory and to control the machine spindle to shape the workpiece into the final configuration. At least one of the spindle attachments includes a static assembly and a rotating assembly mounted on and extending through the static assembly. The rotating assembly includes a spindle having an upper end and an application tip, wherein the spindle extends through the static assembly and the application tip projects out of a lower end of the static assembly, the spindle configured to rotate on a spindle axis relative to the static assembly, a material supply mounted on the spindle, and a wire feeder disposed within the spindle, the wire feeder configured to engage a wire extending from the material supply and to draw the wire from the material supply and through the spindle. At least one of the spindle attachments is configured to provide a continuous supply of wire from the material supply to the application tip.

According to yet another aspect of the disclosure, a method of depositing a layer of material on a substrate includes feeding a wire of deposition material to an application tip of a spindle from a reel mounted on the spindle, positioning the wire extending from the application tip in a deposition zone and applying a pressure to the wire in the deposition zone, rotating the spindle relative to the substrate to generate frictional heat where the wire contacts the substrate, and traversing the wire across the substrate to thereby deposit a layer of the wire deposition material on the substrate.

DETAILED DESCRIPTION

FIG. 1is a block diagram of machine system10. Machine system10includes computer numerical control (“CNC”) machine12and computer14. CNC machine12includes tool bank16, machine spindle18, work area20, and heating element22. Computer14includes memory24, processor26, and user interface28. Tool bank16stores subtractive attachments32when not in use and can also store additive attachment30when not in use. Additive attachment30includes wire34and sensors36.

Computer14communicates with CNC machine12via communication link38. Communication link38can be a wired or wireless connection, and it is understood that computer14can be integrated into CNC machine12or disposed separately from CNC machine12. Processor26, in one example, is a digital logic circuit capable of executing software or other instructions, for example, stored in memory24.

Memory24, in some examples, can be configured to store information during operation of computer14. Memory24, in some examples, is computer-readable storage media. In some examples, the computer-readable storage media can include a non-transitory medium, and in some examples can include a volatile medium. In some examples, memory24is configured to store program instructions for execution by processor26.

User interface28, such as a keyboard, touchscreen, monitor, mouse, or other suitable interface device, allows a user to interact with machine system10, such as by retrieving information from memory24, receiving notifications, initiating the software stored in memory24, and inputting additional information to memory24, among other examples. User interface28can also be configured to provide an output of information to the user. For example, user interface28can include a sound card, a video graphics card, a speaker, a display device, or other type of device for outputting information in a form understandable to users or machines.

CNC machine12is an automated, multi-axis machine tool utilized to shape workpiece40into a desired configuration. CNC machine12can be a 3-axis machine, a 5-sided machine, a 5-axis machine, or any other desired configuration, for example. Workpiece40is housed in work area20, and CNC machine12can utilize additive attachment30and subtractive attachments32to shape workpiece40into a desired configuration. Substrate42is the portion of workpiece40that layers of material are deposited on during an additive manufacturing process.

Tool bank16can store additive attachment30and subtractive attachments32when not in use. Both additive attachment30and subtractive attachments32can be connected to and powered by machine spindle18and are configured to shape workpiece into the desired configuration. Additive attachment30can add material to substrate42on workpiece40through an additive manufacturing process. In one example, additive attachment30can be configured to add layers42of material, such as wire34, to substrate42through a solid state additive manufacturing process, such as friction surfacing additive manufacturing (“FSAM”), for example. Sensors36can be disposed in or relative to additive attachment30and can be configured to sense various operating characteristics of additive attachment30, such as an applied load, a temperature of wire34, or any other desired characteristic. Wire34can be of any suitable material for applying to substrate42through the FSAM process. For example, wire34can be metallic, cermet, plastic, or other matrix materials. In some examples, wire34can also include a sheath surrounding a desired particulate material to produce specific matrix composites when wire34is bonded to substrate42during the FSAM process. Wire34can include a metallic sheath surrounding a carbon particulate core, for example. A sheath surrounding a core can effectively lower the melting point of the overall wire34, such that less friction, and thus a slower rotational speed, is required to plasticize wire34for application during the FSAM process. Moreover, wire34can be of any desired cross-sectional shape, such as a circle, square, triangle, or any other suitable shape.

Subtractive attachments32can remove material from workpiece40, such as through grinding, milling, or drilling, for example. Machine spindle18can utilize both additive attachment30and multiple subtractive attachments32from tool bank16, and machine spindle18can automatically attach to and detach from both additive attachment30and subtractive attachments32. As such, CNC machine12is configured to shape workpiece40utilizing various machining attachments and methods.

During an FSAM process, a sacrificial wire or rod of deposition material, such as wire34, is rotated relative to a substrate, such as substrate42, and is applied to the substrate with a desired pressure. Friction between the deposition material and the substrate generates heat. The temperature and pressure are controlled, such as by computer14, to prevent the deposition material from melting and undergoing a phase change. Instead, the heat builds to an FSAM setpoint, which is typically about 70-90% of the melting point of the deposition material. The FSAM setpoint can be any suitable temperature for plasticizing the deposition material and for providing desired properties at an interface between individual layers, such as layers44, and at an interface between individual layers and the substrate. Plasticizing the deposition material generates a viscoelastic boundary layer at the tip of the sacrificial wire. The sacrificial wire is then traversed across the substrate and deposits a layer of deposition material on the substrate.

The temperature and pressure conditions during the FSAM process lead to an inter-diffusion process resulting in a bond between the plasticized material and the substrate. Because the sacrificial wire does not melt, the sacrificial wire does not undergo a phase transformation and the microstructure gradient of the deposited wire material on the substrate can thus be controlled as a function of the rotational speed, the applied load, and the traverse speed. FSAM thus enables the generation of defect-free parts with high interfacial shear strength and a controlled microstructure gradient that enhances the mechanical hardness of components produced using FSAM. A heating element, such as heating element22, can be utilized to preheat the sacrificial wire such that less friction and pressure are required to raise the temperature of the sacrificial wire to the FSAM setpoint.

During operation, information regarding the desired configuration of workpiece40is input into computer14, such as via user interface28, and can be stored in memory24. Processor26can execute the instructions stored in memory24to cause CNC machine12to shape the workpiece40. Workpiece40is placed in work area20and CNC machine12is activated. Computer14instructs CNC machine12to select additive attachment30or subtractive attachments32from tool bank16. CNC machine12maneuvers machine spindle18and machine spindle18attaches to additive attachment30or subtractive attachment32. Machine spindle18powers the selected one of additive attachment30and subtractive attachments32to shape workpiece40.

During operation to add material to substrate42, computer14instructs CNC machine12to select additive attachment30. Machine spindle18drives the rotation of additive attachment30and positions additive attachment30relative to substrate42. Additive attachment30is lowered and wire34contacts substrate42. Machine spindle18applies a load to additive attachment30thereby applying pressure to wire34on substrate42. When the temperature and pressure of wire34are at the FSAM setpoint, which can be sensed by sensors36, machine spindle18traverses relative to workpiece40to deposit layers44of wire34on substrate42. Computer14controls the rotational speed of additive attachment30, the load applied, and the traverse speed of machine spindle18relative to workpiece40.

The structure of the layers44of wire34deposited on substrate42can be altered by controlling, for example, the rotating speed, the traverse speed, and the applied load. Sensors36can provide feedback to computer14to allow computer14to adjust the operating parameters of machine spindle18to thereby control the properties of layers44. In some examples, sensors36can sense the applied load, the heat generated by the FSAM process, the temperature of wire34, and the pressure on wire34, among others. Sensors36can communicate the information to computer14or can utilize the information to control various internal components within additive attachment30. The material of wire34and the material of substrate42can be stored in memory24and computer14can control additive attachment30to provide a desired microstructure. For example, computer14can be loaded with instructions that, when executed by processor26, cause CNC machine12to alter the rotating speed, traverse speed, and applied load to produce a boundary layer with the desired material properties in the deposition zone. As such, additive attachment30and CNC machine12allow for online optimization of the processing parameters to provide adequate quality of solid state bonding between wire34and substrate42for fine feature deposition or repair layers.

With additive attachment30, CNC machine12can be a hybrid additive/subtractive machine that allows for a single machine to complete both additive and subtractive processes on a single workpiece40. For example, CNC machine12can remove material from workpiece40using various subtractive attachments32. CNC machine12can also add material to workpiece40through an FSAM process with additive attachment30. CNC machine12can machine the material added through the FSAM process into a desired configuration with subtractive attachments32. As such, CNC machine12can both add and subtract material from workpiece40to produce workpiece40having the desired form.

Additive attachment30provides significant advantages. Additive attachment30allows any multi-axis CNC machine to function as an additive manufacturing machine. Additive attachment30facilitates a relatively simple transition from a subtractive machining tool to a hybrid additive/subtractive machining tool, thereby reducing machine costs and complexity in the manufacturing process. Moreover, enabling a single CNC machine to perform both additive and subtractive tasks enables a single CNC machine to fully shape a workpiece without requiring the user to remove the workpiece and to utilize different machines, thereby simplifying and shortening the manufacturing process. Furthermore, various material parameters can be stored in memory24, and the material properties of any deposition layer can be customized by controlling one or more of the rotating speed, the traverse speed, and the applied load of the wire on the substrate. Computer14can also receive feedback from sensors36and adjust the operating parameters, such as rotational speed, traverse speed, and applied load, to alter the properties of the deposited layers.

Rotating assembly46is rotatably mounted on static assembly48. Mounting flange92extends radially from static assembly48and can be used to attach additive attachment30to a machine for use. Spindle50extends through static assembly48, and application tip70projects out of a lower end of static assembly48. Bearing62is disposed between spindle50and static assembly48and supports rotating assembly46for rotation relative to static assembly48. In some examples, bearing62radially supports spindle50relative to axis A-A, but it is understood that bearing62can provide radial support, axial support, or both. Angular bearings68are disposed between spindle50and static assembly48, with angular bearings68disposed proximate application tip70of spindle50. Angular bearings68can provide both radial and axial support to spindle50. Balance ring54is mounted on spindle50below material supply52and is configured to absorb vibrations experienced by additive attachment30, thereby minimizing any adverse effects that can be caused by the vibrations. Drive pulley60is mounted on spindle50and can receive a device, such as a belt, chain, clamp, or any other suitable device for rotating drive pulley60and thus for driving the rotation of rotating assembly46.

Material supply52is mounted on upper portion72of spindle50outside of static assembly48. Mount bracket76is connected to upper portion72of spindle50, and reel74is rotatably supported by mount bracket76. Similarly, follower78is mounted on mount bracket76, and follower78is configured to guide wire34between reel74and guide wheels56. Wire34wraps around reel74and extends from reel74, through follower78, and into spindle50. Wrapping wire34on reel74provides a feedstock of wire34for use throughout an FSAM process, such that the FSAM process does not require stopping and starting to reload additive attachment30with additional wire34. Material supply52provides continuous feeding of wire34throughout the FSAM process to allow for uninterrupted deposition of layers44of wire34on substrate42. Some materials deposited during the FSAM process can oxidize in the interim if it is required to insert a new rod of material for use in the FSAM process after a previous rod has been consumed. The oxidation can lead to weaker bonding between layers44. Continuously feeding wire34throughout the FSAM process prevents oxidation from occurring on previously deposited layers because the continuous feeding eliminates the need to stop the FSAM process and insert a new rod of material for application to the substrate.

Wire34can be of any suitable material for applying to substrate42through the FSAM process. For example, wire34can be metallic, cermet, or other matrix materials. In some examples, wire34can also include a sheath surrounding a desired particulate material to produce specific matrix composites when wire34is bonded to substrate42during the FSAM process. Wire34can include a metallic sheath surrounding a carbon particulate core, for example. A sheath surrounding a core can effectively lower the melting point of the overall wire34, such that less friction, and thus a slower rotational speed, is required to plasticize wire34for application during the FSAM process. Moreover, wire34can be of any desired cross-sectional shape, such as a circle, square, triangle, or any other suitable shape.

Wire feeder64is disposed within spindle50and configured to control the feed of wire34through spindle50. Motor80is mounted within spindle50and transmission gear84is connected to and powered by motor80. In some examples motor80is an electric motor. In some examples, motor80is connected to and controlled by computer14(shown inFIG. 1). Balance weight82is disposed on an opposite side of spindle50from motor80and is configured to offset a mass of motor80to balance spindle50during rotation. Transmission gear84is connected to and driven by motor80. Transmission gear84meshes with feeder wheels86and provides rotational power to feeder wheels86. Transmission gear84can be of any suitable configuration for transmitting power to feeder wheels86, such as a worm gear or toothed gear, for example. While motor80is described as providing rotational power through transmission gear84, it is understood that motor80can provide rotational power in any desired manner, such as through a direct connection with one or more feeder wheels86or through any desired form of intermediate gear. In some examples, wire feeder64includes multiple, intermeshed feeder wheels86. Where wire feeder64includes multiple feeder wheels86, it is understood that wire feeder64can include intermediate gears, such as intermediate gear88, between feeder wheels86to ensure that feeder wheels86all rotate in the same direction. Rotating feeder wheels86in the same direction allows feeder wheels86to exert a downward force on wire34to ensure that wire34is properly positioned and adequately fed for application throughout any FSAM process. Idler wheels90are disposed on an opposite side of wire34from feeder wheels86and are configured to ensure wire34engages feeder wheels86.

Feeder wheels86can engage wire34to pull wire34through spindle50and to resist torqueing of wire34due to the friction generated between wire34and substrate42. Feeder wheels86pull wire34from reel74and provide wire34at tip70throughout the FSAM process, thereby ensuring that a continuous supply of wire34is available throughout the FSAM process. In some examples, feeder wheels86can include teeth to engage wire34. In some examples, feeder wheels86and idler wheels90can include intermeshed teeth such that rotation of feeder wheels86drives the rotation of idler wheels90, with wire34passing between feeder wheels86and idler wheels90and engaging a second set of teeth. It is understood, however, that feeder wheels86can engage wire34in any suitable manner. Feeder wheels86engaging wire34also provides torque resistance to wire34to prevent wire34from torqueing due to the friction experienced in the FSAM process. Limiting any torqueing of wire34to the distance between substrate42and feeder wheels86prevents wire34from being damaged by excess torque. Idler wheels90maintain the engagement of wire34and feeder wheels86.

Feeder wheels86ensure a short, unsupported length of wire34extending to substrate42, which enables additive attachment30to utilize a small-diameter wire for the FSAM process. The short length of wire34between feeder wheels86and substrate42prevents wire34from buckling due to the heat and pressure experienced during the FSAM process. Feeder wheels86thus allow additive attachment30to utilize wires having diameters similar to typical weld wires, such as wires having diameters of about 1.5 mm, for example. Facilitating the use of smaller-diameter wires allows additive attachment30to utilize standard, readily available wires for the FSAM process.

Cooling jacket66is disposed proximate to tip70of spindle50. After exiting wire feeder64wire34extends through cooling jacket66and exits spindle50through tip70. Cooling jacket66can be filled with a cooling substance, such as water, for example, and is positioned to dissipate the heat radiating from wire34during the FSAM process. As discussed above, wire34is heated to near the melting point of wire34, such as about 70-90% of the melting point of wire34, during the FSAM process. Cooling jacket66prevents the heat in wire34from radiating into additive attachment30, which could cause damage to various components of additive attachment30, such as angular bearings68, for example.

During operation, additive attachment30is positioned relative to substrate42and spindle50is driven to rotate on axis A-A and to apply a layer of wire34material on substrate42. Wire feeder64pulls wire34from reel74and through spindle50to position wire34outside of tip70and into the deposition zone proximate substrate42. With spindle50rotating on axis A-A, additive attachment30is lowered towards substrate42and wire34is applied to substrate42with a desired pressure.

Wire feeder64continuously provides additional wire34for deposition on substrate42. Feeder wheels86drive wire34towards tip70to assist in maintaining the pressure of wire34on substrate42. Feeder wheels86pull wire34from reel74and position the end of wire34at tip70such that the end of wire34is proximate substrate42and positioned to add layers44of wire34to substrate42. The feed rate of wire34is controlled by motor80, which supplies rotational power to feeder wheels86through transmission gear84. Transmission gear84drives feeder wheels86, and feeder wheels86pull wire34from reel74, through guide wheels56and guide tube58, and push wire34out of spindle50through tip70.

The friction and pressure applied to wire34cause heat to build at the tip of wire34. The heat builds until the temperature reaches the FSAM setpoint. Additive attachment30traverses substrate42, and layers44of wire34are deposited on substrate42. To generate the heat required to plasticize wire34for application during the FSAM process, additive attachment30can include a heating element, such as heating element22(shown inFIG. 1). The heating element can raise the temperature of wire34such that less friction and pressure are required to raise the temperature of wire34to the FSAM setpoint. In one example, additive attachment30can include an in-situ heating element, such as by conducting electricity through one of feeder wheels86or idler wheels90, to pre-heat wire34for application. In some examples, a heating element is disposed outside of additive attachment30and focuses energy in the deposition zone to provide additional heat to wire34. When the temperature of wire34reaches the FSAM setpoint, layers44can be deposited on substrate42through the continued application of pressure and by traversing wire34across substrate42. Layers44can be stacked on substrate42and can be machined into a final form.

Additive attachment30thus provides continuous feeding of wire34throughout the FSAM process. Additive attachment30is attached to a machine to allow the machine to perform a FSAM process and thereby add layers of material, such as wire34, to a substrate, such as substrate42. In some examples, additive attachment30is a tool attachment for a multi-axis CNC machine, such as CNC machine12(shown inFIG. 1), and is positioned by a machine spindle, such as machine spindle18(shown inFIG. 1), and controlled by a computer, such as computer14. For example, computer14can manipulate machine spindle18to control the rotational speed, the applied load, and the traverse speed of wire34relative to substrate42. In one example, machine spindle18can cause spindle50to rotate around axis A-A through drive pulley60. It is understood, however, that machine spindle18can drive the rotation of spindle50in any suitable manner. In some examples, spindle50is an attachment for an on-site repair machine. For example, spindle50can be attached to a manipulator arm and can be used to deposit material on various parts from various angles, thereby allowing an FSAM process to be used for on-site maintenance and repair.

Additive attachment30provides significant advantages. Additive attachment30provides for continuous feeding of wire34throughout the FSAM process. The FSAM process deposits layers44of wire34on substrate42without requiring wire34to undergo a phase transformation. By avoiding a phase transformation, the microstructure gradient in the deposition layer can be controlled as a function of rotating speed, traverse speed, and applied load. FSAM further produces porosity-free layers with high interfacial bond strength. As such, FSAM produces defect free components having high interfacial shear strength and a controlled microstructure gradient. Continuously feeding wire34throughout the FSAM process eliminates the need to stop manufacturing to insert a new wire, henceforth eliminating oxidation and the weakening of bonds that can occur in previously deposited layers. Moreover, additive attachment30provides a short length of unsupported wire34outside of spindle50. The short length of unsupported wire34reduces buckling of wire34thereby allowing smaller-diameter wires to be utilized for the FSAM process, providing cost savings. In addition, additive attachment30can be utilized on any suitable machine such that any machine capable of utilizing subtractive attachments32(shown inFIG. 1) can also utilize additive attachment30to provide additive manufacturing capabilities. Additive attachment30thus reduces costs associated with additive manufacturing as a specialized machine is not required, and reduces the time required to produce a finished part as a single machine can both add and subtract material from substrate42. Moreover, additive attachment30can be utilized for on-site additive repair of parts.

Discussion of Possible Embodiments

A spindle attachment includes a static assembly and a rotating assembly mounted on and extending through the static assembly. The rotating assembly includes a spindle having an upper end and an application tip, wherein the spindle extends through the static assembly and the application tip projects out of a lower end of the static assembly, the spindle configured to rotate on a spindle axis relative to the static assembly, a material supply mounted on the spindle, and a wire feeder disposed within the spindle, the wire feeder configured to engage a wire extending from the material supply and to draw the wire from the material supply and through the spindle. The wire feeder is configured to provide a continuous supply of wire from the material supply to the application tip during an additive manufacturing process.

The spindle attachment of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

The material supply includes a bracket mounted on the upper end of the spindle, and a reel rotatably supported on the bracket, wherein the wire is disposed on the reel.

A guide roller disposed within the spindle, wherein the wire extends through the guide roller between the reel and the wire feeder.

A guide tube disposed within the spindle between the wire feeder and the guide roller on the spindle axis.

The wire feeder includes a motor and at least one feeder wheel powered by the motor, the at least one feeder wheel configured to engage the wire extending from the material supply and to draw the wire from the material supply and through the spindle.

The wire feeder includes at least one idler wheel disposed on an opposite side of the spindle axis from the at least one feeder wheel, the at least one idler wheel configured to maintain an engagement of the wire and the at least one feeder wheel.

The wire feeder includes a drive gear disposed between the motor and the at least one feeder wheel, the drive gear configured to provide rotational power to the feeder wheel from the motor.

The wire feeder includes a balance weight disposed within the spindle opposite the motor.

An angular bearing disposed between the spindle and the static assembly proximate the application tip of the spindle, wherein the angular bearing is configured to both radially and axially support the spindle.

The spindle includes a cooling jacket disposed at the application tip, the cooling jacket extending around the wire and disposed proximate the angular bearing.

A balance ring extending around the upper portion of the spindle and disposed proximate the material supply.

A drive pulley disposed on a portion of the spindle extending out of the static assembly.

A computer numerical control machine includes a work area configured to house a workpiece to be shaped into a final configuration, a plurality of spindle attachments configured to shape the workpiece, a machine spindle configured to attach to and manipulate a position and rotation of the plurality of spindle attachments, and a controller communicatively connected to the machine spindle, the controller configured to receive and store the final configuration in a memory and to control the machine spindle to shape the workpiece into the final configuration. At least one of the spindle attachments includes a static assembly and a rotating assembly mounted on and extending through the static assembly. The rotating assembly includes a spindle having an upper end and an application tip, wherein the spindle extends through the static assembly and the application tip projects out of a lower end of the static assembly, the spindle configured to rotate on a spindle axis relative to the static assembly, a material supply mounted on the spindle, and a wire feeder disposed within the spindle, the wire feeder configured to engage a wire extending from the material supply and to draw the wire from the material supply and through the spindle. The at least one of the spindle attachments is configured to provide a continuous supply of wire from the material supply to the application tip.

The computer numerical control machine of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

At least one sensor disposed in the at least one of the spindle attachments, the at least one sensor configured to sense an operating characteristic of the wire and to communicate the operating characteristic to the controller.

The material supply includes a bracket mounted on the upper end of the spindle and a reel rotatably supported on the bracket, wherein the wire is disposed on the reel, a guide roller is disposed within the spindle, a guide tube disposed within the spindle and on the spindle axis between the wire feeder and the guide roller, and the wire extends through the guide roller and the guide tube between the reel and the wire feeder.

The wire feeder includes a motor, at least one feeder wheel powered by the motor, the at least one feeder wheel configured to engage the wire extending from the material supply and to draw the wire from the material supply and through the spindle, and at least one idler wheel disposed on an opposite side of the spindle axis from the at least one feeder wheel, the at least one idler wheel configured to maintain an engagement of the wire and the at least one feeder wheel.

A cooling jacket disposed at the application tip of the spindle, an angular bearing disposed between the spindle and the static assembly proximate the application tip of the spindle, the angular bearing configured to both radially and axially support the spindle, the cooling jacket extends around the wire and is disposed between the wire and the angular bearing.

A method of depositing a layer of material on a substrate includes feeding a wire of deposition material to an application tip of a spindle from a reel mounted on the spindle, positioning the wire extending from the application tip in a deposition zone and applying a pressure to the wire in the deposition zone, rotating the spindle relative to the substrate to generate frictional heat where the wire contacts the substrate, and traversing the wire across the substrate to thereby deposit a layer of the wire deposition material on the substrate.

Engaging the wire with at least one feeder wheel disposed within the spindle, drawing the wire off of the reel with the feeder wheel, and pushing the wire out of the application tip with the feeder wheel.

Aligning the wire of deposition material on a spindle axis with a guide wheel mounted in an upper portion of the spindle, and passing the wire of deposition material through a guide tube disposed between the guide wheel and the at least one feeder wheel.