ADVANCED MATERIALS & PROCESSES | JULY/AUGUST 2025 42 iTSSe TSS iTSSe TSS a virtual cell (or “digital twin”) looks like in the software. It can generate toolpaths for techniques such as cold spray additive manufacturing and expands its capabilities into other methods used in refurbishment and repair, including wire arc additive manufacturing and laser metal deposition. Continuous3D also includes a task scheduler and supports offline simulation, enabling autonomous operation with minimal human intervention. Working directly from real-time scan data eliminates the need for CAD models and reduces errors from outdated engineering drawings. Overall, Continuous3D enhances efficiency, precision, and flexibility in robotic manufacturing and repair workflows. When Continuous3D software is fully integrated into a robotic cell, it enables a more dynamic workflow. The software communicates directly with both the robot controller and sensors, creating a seamless interaction between hardware and software. For example, a laser profiler (or a different scanning modality) can be used to perform 3D scanning of the workpiece either by having the system stationary or mounted on a robot. This real-time data allows the system to adapt toolpaths and operations based on the actual condition of the part. Figure 3 Fig. 3 — Automated repair of a magnesium casting (automotive engine block) using Continuous3D in two di erent configurations: with a cold spray gun stationary and mounted on a robot. Similarly, two robots could be holding the cold spray gun and the component, respectively, thus providing 12 degrees of freedom for maneuverability. The capabilities can be extended to post-machining operations. shows an example of an aluminum cold spray repair on a magnesium-casting enabled by Continuous3D. In this case, the operations have been instructed by the operator without a digital CAD model of the selected component. Instead, the software assisted the operator in extracting a region of interest directly from the scanned data. That region was used to produce a toolpath and drive the process from the software. CONCLUDING REMARKS Automation is revolutionizing the field of metal component refurbishment, offering unparalleled benefits in precision, efficiency, and sustainability. By adopting automated workflows, industries can enhance their competitiveness and meet the demands of a fast-paced, quality-driven market. In particular: • One-o repairs require advanced sensing and techniques to accommodate the unique conditions of individual components. • Digital tools and robotics can significantly enhance the consistency, speed, and quality of metal component refurbishment. FEATURE 8
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