Machine tools combine material addition via ultrasonic object consolidation
and subtractive techniques for imparting high-dimensional accuracy to a
finished object. A material supply and feeder, ultrasonic horn, and
feedstock cutting device are integrated with a material removal subsystem
preferably including a cutting tool and an excess material removal system.
Any metal, plastic or composite material suitable for ultrasonic joining
may be employed as a feedstock, and these material may assume the form of
tapes, sheets, wires, filaments, dots or droplets, with the feeding and
material cutting components being designed for the specific feedstock
employed. The cutting tool for excess material removal, may be a knife,
drill/mill, grinding tool, or other tool capable of accurately cutting the
external contour of a cross section of the part being built, and for
removing excess feedstock remaining following the application process. The
material removal could consist of a vacuum or blower system, chip auger,
or other suitable apparatus. A machine disclosed as part of the preferred
embodiment is able to deposit material in one step, and optionally and
selectively remove it in another. Through the expeditious combination of
deposition and removal, the fabrication of objects of arbitrary shape may
be realized.