System and Method for Repairing Damaged Parts with Integrated Removal and Deposition

A system for repairing a damaged part with integrated removal and deposition, comprising:

• a scanning unit configured to generate high-density point cloud of the damaged part;
• a material removal unit to remove material from the damaged part;
• a deposition head assembly configured to restore damaged areas by adding material;
• and
• a controller configured to:
• compare the damaged part's point cloud with a reference model;
• identify location requiring material deposition to restore damaged part;
• identify obstructions to the material deposition at the identified location requiring material deposition and clear identified obstruction by a removal process using the material removal unit;
• deposit repair material using a droplet-based deposition head assembly to restore the identified location requiring material deposition;
• and
• iteratively rescan the damaged part and updating the damage part point cloud to refine subsequent removal and deposition steps,
• wherein the removal and deposition processes are dynamically adjusted based on the updated damage part point cloud.

A method for repairing a damaged part, comprising:

• scanning the damaged part to generate a high-density point cloud representing the geometry of a damaged surface of the damaged part;
• comparing the damaged part point cloud with a reference model of the undamaged part to identify a deposition location requiring material deposition to restore the geometry;
• depositing repair material using a deposition head assembly at the deposition location;
• and
• iteratively rescanning the damaged part and updating the damaged part point cloud to identify next deposition locations for next deposition step,
• wherein the deposition process is dynamically adjusted based on the updated damage part point cloud.