Handheld 3D Printer for Precision Cold Spray Repair
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Solution Overview
Problem
Current cold spray technologies for surface repair lack precision and efficiency, as operators must manually estimate material deposition, leading to overbuilding, underbuilding, and increased waste, with safety concerns and difficulty in accessing constrained repair areas.
Innovation Solution
A handheld device using visual fiducials and scanning technologies (LADAR, stereo, or structured light sensors) to localize the nozzle and automatically control material flow based on real-time comparisons between the scanned part and a model, ensuring accurate deposition of materials like metals and ceramics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual material deposition control is used, then ease of operation is maintained, but manufacturing precision deteriorates due to overbuilding and underbuilding
Solution Approach 1:
The patent replaces manual mechanical control of material deposition with an automated system that uses optical sensors (camera) and computational algorithms to detect part geometry and control material flow. The mechanical adjustment mechanism is substituted with digital image processing and automated control, enabling precise material deposition without manual intervention.
Solution Approach 2:
The patent implements a feedback loop where the camera continuously captures images of the part during deposition, the system processes these images to determine material distribution, and adjusts material flow accordingly. This closed-loop feedback mechanism enables real-time precision control of material deposition based on actual part geometry and deposition status.
2Manufacturing precision
If automated material deposition control is implemented, then manufacturing precision is improved, but ease of operation deteriorates due to complexity
Solution Approach 1:
The system performs self-service by automatically detecting part geometry, determining deposition requirements, and controlling material flow without operator intervention. The automated camera-based system independently analyzes the part structure and manages the deposition process, eliminating the need for skilled operators to manually control material application.
Solution Approach 2:
The patent introduces an intermediary computational layer between the operator and the deposition process. The camera and processing system act as intermediaries that translate physical part geometry into digital models and deposition commands, shielding the operator from complexity while maintaining precise control through automated mediation.
3Loss of substance
If manual material deposition is used, then device complexity is reduced, but loss of substance increases due to waste from overbuilding
Solution Approach 1:
The patent replaces manual mechanical material application with an automated optical and computational system that precisely controls material flow. The substitution of mechanical guesswork with digital imaging and algorithmic control enables exact material placement, minimizing waste from overbuilding while maintaining acceptable system complexity through integration of camera and control systems.
Solution Approach 2:
The system applies material selectively and partially only where needed based on real-time image analysis, rather than applying excessive material manually. The automated detection allows precise partial deposition matching the actual repair requirements, reducing material waste while the system complexity is offset by the efficiency gains from reduced rework and material savings.
4Measurement precision
If visual fiducials and scanning technologies are used, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent uses visual fiducials as intermediary reference markers that bridge the physical part and the digital measurement system. These simple fiducial markers enable the camera-based scanning system to accurately localize and measure part geometry without requiring complex integrated measurement apparatus, thereby improving measurement precision while limiting the increase in device complexity to simple reference markers rather than complex sensing systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances precision and safety by automating material deposition, reducing waste, and enabling accurate repair in constrained spaces, while improving the aesthetics and physical properties of the repaired parts.
Implementation Method 1
A LADAR, stereo, or structured light sensor is used to measure the amount of material being deposited
Implementation Method 2
visual fiducials are used. Fiducials are markers that are placed on the part that can be read from a sensor on the nozzle
Implementation Method 3
Cold spray uses gas to accelerate metal powders usually in the Sum to 100 um to supersonic speeds
Implementation Method 4
The process is most important when repairs need to be performed in situ. Cold spray uses gas to accelerate metal powders usually in the Sum to 100 um to supersonic speeds
Implementation Method 5
As the accelerated particles hit the substrate material, they plastically deform and deposit onto the substrate to create bonds
Implementation Method 6
Cold spray uses gas to accelerate metal powders usually in the Sum to 100 um to supersonic speeds. As the accelerated particles hit the substrate material, they plastically deform and deposit onto the substrate to create bonds
Data Source
AI summary
A device is described where an operator uses a handheld nozzle that deposits new material onto a part. The process can be used to create new parts from a substrate, or to repair parts. The device automatically maps the physical part and matches the physical part against a model of the desired part. As the operator moves the nozzle over the part, the device automatically computes the amount of material necessary to modify the current part to match the model of the desired part. This method can be used for spraying or spray-casting metal, ceramics, and other materials. The described process and device automates this process, and simplifies the operator's involvement. Moreover, because the device can measure the part as the material is being deposited, the resulting part is more likely to more closely resemble the original part both in aesthetics and physical properties.