iTSSe TSS ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 41 iTSSe TSS FEATURE Fig. 1 — Robotic metal repair and, more broadly, robotic additive manufacturing (AM) is an ecosystem where different disciplines in the physical and digital domains converge to enable and simplify industrial processes. Techniques such as cold spray and direct energy deposition (DED) processes are good examples of this. Challenges co-existing in the physical and virtual world are, in principle, applicable to any deposition technique. The software is hardware-agnostic, supporting various industrial robots and both additive and subtractive manufacturing methods. Figure 2 shows an example of what challenges, it holds transformative potential for enhancing efficiency, quality, and safety in industrial maintenance. ENABLING WORKFLOW SIMPLIFICATION The Commonwealth Scientific and Industrial Research Organization (CSIRO), Australia’s national science organization, has been working for several years on ways to realize the potential of automation in refurbishment and repairs to boost quality, productivity, and safety. CSIRO has developed Continuous3D, an advanced digital platform designed to automate complex metal repair and additive manufacturing tasks using robotics (https://research. csiro.au/continuous3d/). This system integrates software, sensors, and robotic equipment into a cohesive unit capable of scanning, analyzing, and repairing damaged workpieces without manual programming or extensive measurements. At its core, Continuous3D uses machine vision and patented algorithms to interpret 3D scans and generate continuous, non-intersecting toolpaths for material deposition. This approach is particularly effective for processes like cold spray and other high-energy metal deposition techniques, where traditional toolpaths are inefficient. Fig. 2 — A virtual automated repair cell in the Continuous3D software using a cold spray and laser scanner mounted on a robot. *CAD model courtesy of Centerline (Windsor) Ltd. 7
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