Advanced Robotic Automation for Repair, Metal Forming, and Welding via Directed Energy Deposition (DED)

FormAlloy's proposal centers on the integration of advanced robotic automation with our existing Directed Energy Deposition (DED) processes to revolutionize repair, metal forming, and welding tasks critical to maintaining the operational readiness and longevity of naval aviation assets. DED technology, which can utilizing both powder and wire feedstock, offers unparalleled precision and flexibility in metal deposition, enabling the repair and enhancement of both complex and simple geometries. FormAlloy's approach will leverage commercially available and state-of-the-art robotic systems to automate these processes, ensuring consistent quality, reducing human error, and significantly decreasing downtime.The advanced robotic integration platform will be capable of:Automated Repair: Implementing pre- and post-repair inspection and path generation algorithms, our system can generate optimal repair toolpaths, execute precise material deposition to the appropriate location, and perform post-deposition inspection to enable restoration of components to their original specifications. This capability is particularly beneficial for extending the life cycle of landing gear, turbine blades, and other critical parts.Metal Forming: By automating pre-scanning, toolpath generation, DED processing, and post-repair inspection, FormAlloy can perform in-situ repairs that adapt to the unique geometries and material properties required in aviation maintenance and support downstream quality assurance and processing. The FormAlloy system's ability to deposit dissimilar materials may further enhance the performance and durability of repaired or newly formed parts.Welding: Our robotic platform will provide precision welding applications, providing superior control over the heat input and deposition rates, which are critical for maintaining the structural integrity of aviation components. This is essential for repairing cracks, joining dissimilar metals, and performing complex welds with minimal distortion.FormAlloy's solution is designed to seamlessly integrate into existing maintenance workflows, offering a scalable and modular approach that can be tailored to the Navy's specific needs. The use of advanced sensors and FormAlloy's DEDSmart® suite ensures real-time monitoring and adaptive control, enhancing the reliability and efficiency of the repair and manufacturing processes. The data that is output can assist with and accelerate the qualification process, aiding in technology adoption.The anticipated benefits of implementing this advanced robotic DED system include Reduced Maintenance Time, Improved Component Longevity, and Cost Savings.FormAlloy is committed to advancing the capabilities of the Navy's aviation maintenance operations.  Our proposal aims to deliver a robust, versatile, and efficient solution that meets the rigorous demands of naval aviation maintenance, ensuring mission readiness and operational excellence.