In some aspects, material processing head can include a body; an antenna disposed within the body; a first tag, associated with a first consumable component, disposed within a flux communication zone of the body at a first distance from the antenna, the first tag having a first resonant frequency; and a second tag, associated with a second consumable component, disposed within the flux communication zone of the body at a second distance from the antenna, the second tag having a second resonant frequency that is different than the first resonant frequency, where the first and second resonant frequencies are tuned based upon at least one of: i) a difference between the first distance and the second distance; or ii) a characteristic (e.g., shape) of the flux communication zone in which the first tag and/or the second tag is disposed.

A method of producing a 3D article by additive manufacture is provided. The method includes the steps of: forming a meltpool in an already-existing part of the article, and moving the meltpool relative thereto; feeding a directed feedstock into the moving meltpool to deposit and fuse a layer of material on the already-existing part; and repeating the forming and moving and feeding steps to build up successive layers of material. In performance of the forming and moving step: a first energy source impinges at a first region of the already-existing part which moves with and leads the meltpool, whereby the first energy source initiates the formation of the meltpool; and a second energy source impinges at a second region on the already-existing part which moves with and follows the first region, whereby the second energy source grows the lateral width of the meltpool before the feedstock is fed therein.

A plasma computer numerically controlled (CNC) cutting machine is controlled by a computers. In an embodiment, the computer executes a CNC program to control movement of a plasma torch to cut parts from a workpiece while a spectrometer determines emissions spectra of light emitted in a brief time window as the torch begins to cut the workpiece. The spectrometer cooperates with the computer to analyze the metal as it is being cut by the CNC cutting machine and determine a composition. In embodiments, the composition is compared to an expected composition and saved in a database with identifying information; in a particular embodiment the database is queried to provide identifying information of metal having similar composition to the workpiece.

A nozzle gas flow sensor and a method thereof are provided. The nozzle gas flow sensor includes circuitry configured to receive sensing signals (readings) from a sensing element, each indicative of a flow rate of shielding gas ejected from a nozzle of a torch; analyze the flow rate; and evaluate the stability of the flow rate of the shielding gas with a window of operation. The nozzle gas flow sensor may include an indicator indicative of the evaluation result. The torch may be a welding torch, a cutting torch and/or a spraying (coating) torch.

A plasma cutting system for measuring or monitoring the voltage between a plasma torch and the material being cut to determine a voltage or voltage signature and comparing that measurement against predetermined values to indicate that an initial pierce of the material is complete, and based on the measurement, moving the torch or the material to a different location for additional cutting. The system further provides a Fix Drawing Tool, which will automatically detect and fix gaps or overlaps in a drawing that are very difficult to find visually. These gaps and overlaps become a problem when trying to make a proper toolpath because a CAM program requires a clean, closed shape. The system also provides a Dynamic Corner Looping system, which automatically adjusts with the feed-rate and accelerations of the toolpath and plasma machine, eliminates unwanted dross, sharpens corners and minimizes material loss. A pendant tethering system is also disclosed for managing control of a CNC machine remotely. Additional disclosed functionality includes a data collection system, a manual hand wheel with 3D simulation and a multiple fabrication head management system.

A plasma-torch cutting machine gantry moves in a first axis and the torch mounted through a pantograph to a drive box moves along the gantry in a second axis. The drive box rotates the torch about a third axis, and tilts the torch about a fourth axis. The drive box moves vertically in a fifth axis. The torch is mountable with tip at pantograph focal point or in an extended position. A controller firmware computes and apply offsets in the first, second and fifth axis to maintain the plasma torch tip in desired position despite the torch being mounted in extended position, rotation and tilt of the torch. In embodiments the torch is rotatable −/+90 degrees from vertical; and a laser scanner maps surfaces and edges of beams to determine movements and rotations for cutting beams.

The invention features a replaceable cartridge for a plasma arc torch. The cartridge includes a cartridge body having a first section and a second section. The first and second sections are joined at an interface to form a substantially hollow chamber. The interface provides a coupling force that secures the first and second sections together. The cartridge also includes an arc constricting member located in the second section; an electrode included within the substantially hollow chamber; and a contact start spring element affixed to the electrode. The spring element imparts a separating force that biases the electrode toward at least one of the first section or the second section of the body. The separating force has a magnitude that is less than a magnitude of the coupling force.

A multi-loop antenna and an RFID system are used for monitoring tools when machining rotationally symmetric workpieces. A multi-loop antenna is arranged on a tool carrier near a rotationally symmetric tool so that multi-loop antenna encloses the rotationally symmetric tool and the rotationally symmetric tool carries an RFID transponder. The position of this RFID transponder is arranged on the rotationally symmetric tool so that it is arranged in the electromagnetic ring field of the multi-loop antenna. The multi-loop antenna is arranged on the tool carrier so that it is possible to query the RFID transponder on the rotationally symmetric tool in any position while in motion and when at rest.

In some aspects, torch receptacles for coupling a plasma arc torch to a torch lead can include: a body having a first end to connect to the torch lead and a second end to connect to a torch body; a set of ports within the first end to fluidly connect to a set of fluid conduits within the torch lead; and a multiway valve within the body and fluidly connected to the set of ports and to a torch gas conduit formed in the second end, the multiway valve being configured to: i) manipulate a flow of fluids between the first end and the second end to select from primary gases entering the set of ports, ii) deliver a selected primary gas to the torch body through the torch gas conduit, and iii) fluidly connect the torch gas conduit to a gas supply manifold of the plasma cutting system.

A computerized method is provided for automatically determining at least one characteristic of a workpiece for processing by a plasma arc processing system. The method includes electrically connecting the workpiece to the plasma arc processing system that includes a plasma arc torch. A distal tip of the plasma arc torch is configurable to be positioned proximate to the workpiece. The method includes supplying, by the plasma arc processing system, an electrical current with a low amperage to the workpiece, the low amperage current insufficient to cut the workpiece, and monitoring, by the plasma arc processing system, a path of the electrical current relative to the workpiece. The method further includes determining, by the plasma arc processing system, the at least one characteristic of the workpiece based on the electrical current path monitored.