An additive deposition system and method, the system including generating an aerosol of additive material that is charged and deposited onto a selectively charged substrate. Selectively charging the substrate includes uniformly charging a surface of the substrate, selectively removing charged from the substrate to create charged and neutral regions of the substrate surface. The charged regions of the substrate having a polarity opposite a polarity of the charged aerosol. The charged aerosol of additive material deposited onto the selectively charged portions of the substrate surface due to the potential difference between the charged substrate and charged aerosol. The system and method further including repeating the additive deposition process to create a multi-layer matrix of additive material.

A thermosetting powder coating material includes a powder particle containing a thermosetting resin and a thermosetting agent and has a volume particle size distribution index GSDv of less than 1.20 and an average circularity of not less than 0.96.

A thermosetting powder coating material includes a powder particle containing a thermosetting resin and a thermosetting agent and has a volume particle size distribution index GSDv of less than 1.20 and an average circularity of not less than 0.96.