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We are also exploring pathways for the adaptation and further development of existing cold-spray metal additive technologies to lower barriers-to-entry for complex and remote component repair.

Ideal for manufacturers who produce complex foundry castings, remote repair of defence assets, remote manufacture or repair of key infrastructure components, this solution would enable components to be 3D scanned before a build or repair tool path would be automatically generated.

The product

We are researching a prototype of an intelligent cold spray metal additive system with integrated sensing and situational awareness.

This may be customised to benefit manufacturers who make and repair castings, and large or remote metallic structures.

The core technology automated path generation can be applied to many robotic tasks, for example metal and non‑metal additive, or to generate pre-process surface preparation, for example; de-scaling, and post-process for example; grinding, to complete the automated or assisted task.

The system comprises:

  • a robot holding a cold spray metal additive gun
  • machine vision sensors to scan the component surface requiring repair
  • machine vision sensing for situational awareness and collision avoidance
  • a server or cloud based application to create the tool path based on CAD data, and machine vision of the component and near field
  • sensing to control the metal deposition, and
  • cold spray system, power supply and powder feed.

This Automated Robot Tool Path Calculation for Metal Additive Digital Manufacturing and Repair product combines two crucial features for customers.

  1. the ability to scan a component and integrate this information with the robot reference frame and CAD dimensional documentation.
  2. the use of the Continuous3D™ application to automatically generate the robotic tool path for whole component manufacture, or partial repair.

The system is designed to operate in a manufacturing facility or in the field for remote repair.

Proposed benefits

This research is focussed on creating intelligent tools to guide and control robotics, and integrate advanced machine vision, situational awareness, and collision avoidance to deliver a compelling assistive and autonomous solution to complex tasks.

Proposed applications

  • Foundry: Complex castings may include defects which can be certifiably repaired resulting in waste reduction.
  • Defence: Damage to field assets can be quickly and effectively repaired with advanced but relocatable equipment.
  • Construction: Large sub-assemblies can be reliably connected on site in order to facilitate the transport of large structures in road weight allowable sections.
  • Mining: Critical infrastructure in remote hostile locations can be repaired on-site and far more quickly than a back-to-base approach, or relying on access to spare parts.
  • Marine: Large assets suffering corrosion and wear and tear can be effectively repaired in-situ.

If this technology application presents as potential for adaptation or integration to your manufacturing processes, or your business has digital integration challenges that we may be able to assist with, we would love to hear from you. Contact us via the information below.

CSIRO Future Digital Manufacturing

Mrs Sowmya Injeti

Principal Research Consultant (Data61)

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