System and method for fabricating or repairing a part

A method for fabricating a part, comprising:

• generating a solid model representing a three-dimensional part on a computer;
• generating a plurality of electronic two-dimensional layers based on the solid model;
• selecting a deposition system to use for depositing respective two-dimensional layers of material corresponding to each of the electronic two-dimensional layers, the deposition system selected from the group consisting of a welding-based deposition system, a laser-based deposition system, and a plasma powder cladding system, the laser-based deposition system comprising an infrared sensing device operable to sense a molten pool during material deposition by the laser-based deposition system and operable to provide feedback to the computer for substantially real-time control of the molten pool;
• directing a multi-axis robot to obtain a desired deposition device corresponding to the selected deposition system;
• successively depositing, via the selected deposition system, the respective two-dimensional layers of material on a substrate;
• and
• intermittently removing, via a multi-axis milling machine controlled by the computer, material from the three-dimensional part based on the solid model during fabrication.

A system for fabricating a part, comprising:

• a computer operable to control the fabrication of a three-dimensional part using digital engineering data;
• a deposition station operable to deposit successive two-dimensional layers of material to fabricate the three-dimensional part, the deposition station comprising:
• a substrate on which to fabricate the three-dimensional part;
• a welding-based deposition system comprising a welding torch;
• a laser-based deposition system comprising:
• a laser head;
• and
• a powder delivery system comprising a hopper adapted to contain a powder and continuously feed the powder through an output of the hopper, a metering device adjacent the output of the hopper adapted to receive the powder continuously fed through the output of the hopper, a vacuum powder removal device operable to remove the powder from the top surface via a vacuum, and wherein the computer is operable to vary an amount of the powder continuously fed to the metering device in response to monitoring material deposition by the laser-based deposition system;
• a plasma powder cladding system comprising a plasma torch;
• and
• a multi-axis robot operable to, when directed by the computer, utilize one of the welding-based deposition system, laser-based deposition system, and plasma powder cladding system to deposit any of the two-dimensional layers of material;
• and
• a machining station operable to remove at least a portion of one or more of the deposited two-dimensional layers of material, the machining station comprising:
• a multi-axis milling machine;
• and
• an automatic tool changer associated with the milling machine, the milling machine operable to, when directed by the computer, select from a plurality of machining tools associated with the automatic tool changer for use in the milling machine.

A system for fabricating a part, comprising:

• a computer operable to control the fabrication of a three-dimensional part using digital engineering data;
• a deposition station operable to deposit successive two-dimensional layers of material to fabricate the three-dimensional part, the deposition station comprising:
• a substrate on which to fabricate the three-dimensional part;
• a welding-based deposition system comprising a welding torch;
• a laser-based deposition system comprising a laser head and an infrared sensing device operable to sense a molten pool during material deposition by the laser-based deposition system, the infrared sensing device operable to provide feedback to the computer for substantially real-time control of the molten pool;
• a plasma powder cladding system comprising a plasma torch;
• and
• a multi-axis robot operable to, when directed by the computer, utilize one of the welding-based deposition system, laser-based deposition system, and plasma powder cladding system to deposit any of the two-dimensional layers of material;
• and
• a machining station operable to remove at least a portion of one or more of the deposited two-dimensional layers of material, the machining station comprising:
• a multi-axis milling machine;
• and
• an automatic tool changer associated with the milling machine, the milling machine operable to, when directed by the computer, select from a plurality of machining tools associated with the automatic tool changer for use in the milling machine.