Abstract
Abstract Laser cladding or metal deposition (LMD/DED) is widely used for wear-resistant coatings, repair and additive manufacturing applications due to the excellent properties of the deposited material. However, processes on complex 3D surfaces are often a challenge because they require time-consuming programming. This is particularly the case when no CAD data is available for the parts on which metal coatings or structures have to be applied. As a solution, we describe a digital process chain that begins with a 3D scanning process within the laser cladding machine (either robotic or CNC type). Using special software, high-quality 3D models of the scanned parts are created. For coating applications, these models are visualized on a PC. The operator can define cladding areas with just a few clicks of the mouse. Based on predefined parameters, powerful software calculates all the required tool paths. An additional simulation step can be used to verify collision-free operation. Finally, robot or CNC programs are automatically generated that can be executed immediately. Similar software is used to create 3D parts directly from CAD files. Finally, by combining both approaches, 3D geometries can be printed directly onto existing 3D freeform parts using laser metal deposition/LMD, even if their shape is arbitrary and not well documented by CAD data.
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