3D Metal Part Fabrication Using Plasma Powder Deposition Welding

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This patent describes a method and apparatus for additive manufacturing of shaped metal components using plasma powder deposition welding. CAD data of the desired part is automatically sliced into layer contours, and a robot program is generated, optimizing the path for secure and precise layer creation. The system monitors and adjusts the type and amount of metal powder in real-time, using software control. The apparatus includes a moveable chamber that allows for laminar and inert shielding gas flow to protect the process.

Use CasesContent extracted from patent full text and abstract with AI.

• Manufacturing complex metal parts for aerospace, automotive, or medical industries
• Producing customized or small-batch metal components
• Repairing or rebuilding worn or damaged metal parts
• Rapid prototyping of metal objects based on CAD models
• Industrial tooling production with specific material properties

BenefitsContent extracted from patent full text and abstract with AI.

• Enables precise, automated manufacturing of complex metal shapes directly from CAD data
• Improves process reliability and part quality through optimized path and powder control
• Reduces material waste by using additive manufacturing instead of subtractive machining
• Allows for flexible, on-demand production and rapid prototyping
• Provides a controlled environment with protective gas flow, enhancing part properties and reducing oxidation or defects

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Patent Abstract

The invention relates to a method for the generative production of shaped bodies using plasma powder deposition welding, wherein provided CAD data are automatically decomposed into layer contours (slicing) and a robot program for plasma powder deposition welding is created therefrom as a function of process parameters, wherein a component-related path optimization for the process-safe realization of the respective individual layers and subsequently the generative production of the component takes place within the apparatus such that during the deposition process the type and quantity of the metallic powder is controlled and regulated with the aid of software. Furthermore, the invention relates to an apparatus for the generative production of shaped bodies using plasma powder deposition welding, wherein the apparatus has a chamber that is movably sealed upward with a laminar and an inert protective gas supply, wherein a laminar flow can be generated by means of a radially symmetric protective gas supply.