Automating Metal Component Refurbishment – How Can the Power of Digital Tools Boost Quality, Productivity and Safety?

As industries like aerospace and defence seek efficient, reliable solutions for manufacturing and repairs, advanced deposition and coating technologies have become increasingly valuable for creating durable coatings, building 3D structures, and restoring worn or corroded parts. Among these, solid-state processes like cold spray stand out, capable of processing diverse materials such as aluminium and titanium while minimizing thermal stress, distortion, and oxidation, thus preserving original component properties and extending service life. However, many of these processes rely heavily on manual application, posing challenges such as inconsistent quality, dependency on operator skill, limited parameter control, and safety risks. This presentation introduces Continuous3D, a digital manufacturing tool that automates advanced repair and coating processes, delivering high-precision, consistent, and high-quality results while boosting productivity and enhancing operator safety. Practical examples will demonstrate the impact of Continuous3D, showcasing its potential to transform manufacturing and repair practices, address labour shortages, and bridge the workforce skills gap.