Enhancing Cold Spray Additive Manufacturing Through Real-Time 4D Reconstruction for Geometry Control

Cold spray, a high-speed solid-state deposition technique, is widely used for coatings, repairs, and increasingly in additive manufacturing. It enables high productivity by depositing materials at kilogram-scale per hour using robotic arms. However, rapid deposition rates can cause geometry defects, local porosity, and inconsistencies in the final build. These issues arise from the complex interplay of robot kinematics, spray angle, standoff distance, and particle dynamics during deposition. This research integrates in-process spatio-temporal (4D) reconstruction with cold spray to address these challenges. Using a multi-camera setup, the system captures real-time build geometry and employs marker tracking and plane-based registration to correct misalignment and minimize drift. Voxel-based fusion techniques smooth surfaces, enhancing build quality reconstruction. This talk will present a framework for 4D reconstruction and geometry control in cold spray, demonstrating how advanced sensing can improve precision and consistency in automated manufacturing. The results from deployment in a robotic cold spray cell highlight the significant potential of this approach to enhance both repair processes and large-scale 3D part production.