iTSSe TSS ADVANCED MATERIALS & PROCESSES | JULY 2026 41 iTSSe TSS housing (Fig. 2) exhibiting various surface damage was restored. The repair was performed by: • Capturing complex, previously unknown geometries directly in the repair cell • Defining repair regions, including flanges, localized corrosion damage, and internal diameters • Generating validated robotic toolpaths within minutes • Executing cold spray deposition directly from scanned data, without masking or surrogate parts Because scanning, planning, simulation, and execution are unified, the operator’s role shifts from manual programming to process supervision and decision-making, maintaining human oversight while dramatically reducing dependency on specialized robotic expertise. By eliminating the historical reliance on CAD fidelity and manual robot coding, Smart Repair expands robotic cold spray into applications that were previously impractical, uneconomical, or simply too variable and unfeasible to automate. CONCLUSIONS As digital tools, sensing technologies, and robotics continue to evolve, metal refurbishment is moving toward intelligent, adaptive repair systems. Smart Repair aligns directly with this trajectory, providing a practical pathway to scalable automation while preserving the intrinsic advantages of cold spray as a solid-state repair technology. By closing the gap between damaged components and robotic execution, Smart Repair establishes a new level of flexibility and robustness in dimensional restoration, reflecting the realities of modern maintenance, repair, and overhaul operations. ~iTSSe Acknowledgments The foundational science underpinning Continuous3D has been developed by a multidisciplinary team of research scientists and engineers with expertise in robotics, software development, sensing, automation, materials science, cold spray, and advanced processing systems. The authors gratefully acknowledge their contributions. Note: Continuous3D is proprietary software developed by CSIRO. CenterLine Windsor Ltd., Canada, collaborated with CSIRO to demonstrate the Smart Repair concept, combining CenterLine’s Supersonic Spray Technology (SST) equipment with Continuous3D software. For more information: Julio Villafuerte, corporate technology strategist, CenterLine Windsor Ltd., ON, Canada, julio. villafuerte@cntrline.com, www.cntrline.com; Alejandro Vargas-Uscategui, senior research scientist, CSIRO, Clayton, VIC, Australia, www.csiro.au; https://research.csiro.au/ continuous3d. FEATURE KEY TAKEAWAYS Smart Repair is a tool that combines hardware (from CenterLine) and software (Continuous3D) that represents a step change in how cold spray automation can be applied. For repair and refurbishment operations, it enables: • Robotic cold spray without part-specific programming • Effective automation of one-off and low-volume repairs • Improved consistency independent of operator skill • Reduced human exposure to hazardous environments • Faster turnaround and higher asset utilization www.masterbond.com Hackensack, NJ 07601, USA ∙ +1.201.343.8983 ∙ main masterbond.com High Strength Epoxies for Testing Cohesive Strength of FLAME-SPRAYED COATINGS EP15ND-2 for metallic substrates EP15 for ceramic substrates DESIGNED FOR TESTING UNDER ASTM specification C633 HIGH TENSILE STRENGTH > 12,000 psi UNLIMITED WORKING LIFE at room temperature ONE PART, NO MIX SYSTEMS
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