Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided repair of physical structures include: generating a two dimensional difference image from a first three dimensional model of at least one actual three dimensional surface of a manufactured object, and a second three dimensional model of at least one source three dimensional surface used as input to a manufacturing process that generated the manufactured object; obtaining from an image-to-image translation based machine learning algorithm, trained using pairs of input images representing deformed and deformed plus surface defected added versions of a nominal three dimensional surface, a translated version of the two dimensional image; generating from the translated version of the two dimensional image a third three dimensional model of at least one morphed three dimensional surface corresponding to the at least one source three dimensional surface. Further, defects can be removed based on the third three dimensional model.

A process for providing a manufacturing modality for a hybrid article includes defining a model for a build surface on a part in a three dimensional space, and defining a model for an additive structure, the model including an interface surface of the additive structure that corresponds with the build surface in the three dimensional space. The process further includes orienting the x, y and z coordinates of each of the build surface of the part and the interface surface of the model in relation to a three dimensional work space, aligning contours of each of the build surface and the interface surface relative to the work space, and directing a cladding system to define toolpaths for two or more cladding layers that are defined by vertical planar segments or slices of the additive structure model.

A method of machining a surface of a component. The method comprises scanning the surface of the component to obtain scanned electronic 3D data representing the scanned surface of the component locating a surface defect of the scanned surface and identifying a defect region that surrounds and includes the surface defect, and providing electronic 3D data representing a patch having the desired shape of the defect region. The method also comprises transforming the patch to generate a tooling path for repairing the surface defect. The transformation comprising translating a plurality of nodes of the patch. The translation distance of each node based on the distance of that node from an origin node of the patch. The method further comprises machining the surface of the component according to the generated tooling path.

A processing system includes: a processing apparatus configured to perform an additive processing on a plurality of objects; and a control apparatus configured to control the processing apparatus, the control apparatus generates, based on a result of a first measurement operation for measuring a shape of a first object of the plurality of objects, first processing control information for controlling the processing apparatus to perform the additive processing on the first object, the processing apparatus performs, based on the first processing control information, the additive processing on the first object and the additive processing on a second object of the plurality of objects that is different from the first object.

A method of forming at least a portion of an earth-boring tool using an electronic representation of at least one geometric feature of at least a component of an earth-boring tool stored in memory accessible by a processor operatively connected to a multi-axis positioning system, a direct metal deposition apparatus, and a material removal apparatus. The processor generates a deposition path for the direct metal deposition apparatus is based at least in part on the electronic representation of the at least one geometric feature of the at least a component of the earth-boring tool. The direct metal deposition tool is operated according to the generated deposition path to deposit metal material on an earth-boring tool component coupled to the multi-axis positioning system to at least partially form the at least one geometric feature of the earth-boring tool. Methods also include methods of repairing earth-boring tools.

In an approach to improve additive manufacturing embodiments receive, by a sensor set, data associated with an object or a predetermined area, and retrieve, by a knowledge corpus, historic data associated with the object or the predetermined area. Further, embodiments identify a defect on or within an object based on an identified difference in the received data and the historic data and identify, by the sensor set, a target area on the object to repair the defect. Additionally, embodiments, create, by a context-aware robotic system, a physical support around the target area, and repair, by an additive manufacturing mechanism and the physical support, the defect by applying three-dimensional printing-based rectification to the defect.

The present disclosure addresses limitations with methods, systems and processes for integrating multiple advanced technologies into a single automated manufacturing and repair cell. The methods, systems and processes of the present disclosure leverage unique software and hardware to configure a manufacturing cell that is capable of conducting process development and planning, dimensional analysis, pre-machining, surface preparation, cold spray (supersonic particle deposition), dust collection, helium recovery, and post machining in a single integrated manufacturing and repair cell.

A process for providing a manufacturing modality for a hybrid article includes defining a model for a build surface on a part in a three dimensional space, and defining a model for an additive structure, the model including an interface surface of the additive structure that corresponds with the build surface in the three dimensional space. The process further includes orienting the x, y and z coordinates of each of the build surface of the part and the interface surface of the model in relation to a three dimensional work space, aligning contours of each of the build surface and the interface surface relative to the work space, and directing a cladding system to define toolpaths for two or more cladding layers that are defined by vertical planar segments or slices of the additive structure model.

This invention concerns improvements in the inspection, assessment and re-working of manufactured components such as nozzle guide vanes (NGVs) and blades, in particular by improving the comparison of the component with nominal data. Dimensional data of a physical component is obtained and used to create a virtual digitized model of the component which is aligned with a nominal CAD model of the component in a virtual space. The correspondence is assessed and used to adjust weightings of different regions of the digitized model to improve the alignment. This process is repeated within the digital space until either conformance is reached or it is determined that this is not possible.

The present disclosure provides a wafer repair method, system, apparatus and device, and a storage medium, relating to the field of semiconductor devices. The method includes: a laser equipment acquires test data for repairing a predetermined wafer; the laser equipment sending the test data to a processing server so that the processing server converts the test data into repair data in a predetermined format; and the laser equipment obtaining the repair data in the predetermined format to repair the predetermined wafer.