Revolutionizing Repair and Production: An Integrated Modular Cold Spray Additive Manufacturing System

As an emerging additive manufacturing process, cold spray additive manufacturing (CSAM) has attracted considerable attention from researchers. It allows for near-net-shape fabrication of workpieces, but its accuracy and properties often do not meet the user requirements. Additionally, the development of a generalized manufacturing strategy for workpieces with complex geometries is imminent. To address this challenge, various processes involving the entire manufacturing process cycle, from design to delivery, can be integrated. However, few researchers have conducted studies in this area. Therefore, this study developed an efficient and flexible integrated modular CSAM system for the fabrication of workpieces. The system consists of two components: software for modeling and simulation, and hardware for precise fabrication. The software component primarily facilitates the reverse engineering modeling of the workpieces, as well as forming control of the deposits, including automation of path generation and deposits shape prediction before spray. The hardware component, supported by the software’s informational groundwork, actualizes the manufacturing of the workpieces to meet expected quality. The developed system provides a generalized strategy for precision manufacturing of workpieces in CSAM.