ADVANCED MATERIALS & PROCESSES | JULY 2026 40 iTSSe TSS iTSSe TSS FEATURE Scientific and Industrial Research Organization (CSIRO), Australia’s national science agency. The solution includes an integrated scan-to-repair workflow that fundamentally changes how robotic cold-spray restoration is performed. At its core is an intelligent digital platform that allows the system to “see,” interpret, and act on real component geometry. Instead of programming from drawings or CAD files, the system works directly from in-cell 3D scanning, creating a live digital representation of the part as it exists. From this scanned data, regions of interest can be identified, repair protocols defined, and kinematically aware toolpaths generated automatically. These toolpaths are continuous, collision-free, and fully optimized for cold spray deposition, all without manual coding. The result is a seamless transition from scan to spray, executed within a single software environment that connects sensors, software, and robotic hardware. CASE STUDY: INTELLIGENT REPAIR OF A PT6 GEARBOX HOUSING A recent field application highlights the practical advantages of Smart Repair. In this case, a PT6 gearbox Over the years, commercial cold spray equipment has undergone multiple technological advancements to meet evolving industrial demands. Among these developments are capabilities for repair and dimensional restoration using both manual and automated methods (Fig. 1). MANUAL OR ROBOTIC? THE TRADITIONAL TRADE-OFF Cold spray repair can be performed either manually or robotically, depending on the circumstances. For cases where repairs are unique to each component, manual cold spray repair offers unmatched flexibility. Skilled operators can adapt in real time to irregular wear, corrosion, or localized damage. However, this flexibility comes at the cost of variability, operator dependence, and limited scalability. Quality and repeatability are directly tied to experience, availability, and working conditions. On the other hand, in cases where defects are repetitive, robotic cold spray repair delivers repeatability, consistency, and productivity. Once programmed, robots can reproduce spray paths with precision and stability. However, traditional robotic repairs rely heavily on detailed measurements, time-consuming manual programming, and complex fixturing, making them poorly suited for one-off or unpredictable repair scenarios. In industries dominated by unique and diverse component damage scenarios rather than identical damage, this trade-off has long constrained automation. The real challenge has been connecting the real, variably damaged component to automation efficiency and reliability. Every worn component tells a unique story: corrosion pits, distorted flanges, worn holes, and localized material loss that require restoration. Translating these realities into robotic instructions has traditionally required manual intervention, measurements, and trial-and-error. SMART REPAIR: INTELLIGENCE BETWEEN SCAN AND SPRAY Smart Repair is an automated process representing a critical step toward intelligent, adaptive repair cells, unlocking a new level of flexibility and robustness in cold spray-based dimensional restoration. The heart of the process lies in an intelligent AI programming software platform, Continuous3D, developed by the Commonwealth Fig. 2 — Smart Repair of PT6 gearbox housing. Courtesy of Midwest Turbine Services LLC. From top to bottom: View of the Smart Repair cold spray (CS) cell together with digital twin in Continuous3D software; process workflow diagram; and photos of the component before and after CS repair process.
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