Abstract: A laser-aided, direct metal deposition (DMD) fabrication process is used for dies and molds having integrated sensors for monitoring and controlling characteristics that determine the quality of an article being processed. A method of fabricating such devices, as well as the “smart” devices themselves are disclosed. A system of manufacturing articles uses smart dies or smart molds so that various characteristics that affect the quality of the finished article are monitored during the die-forming or injection-molding process. The sensors, which are an integral part of the product-shaping devices, include simple thermocouples for measuring the temperature in various locations, as well as piezoelectric sensors and strain gages to monitor the build-up of stress and strain history caused by fluctuations in temperature during the fabrication process.

Abstract: A system and method for remotely controlling the fabrication of a product at a local manufacturing site. The product is fabricated by depositing successive material layers through a local laser-aided, feedback-controlled, direct material deposition system. The system is equipped with strain gages, optical sensors and acoustic sensors generating signals which are processed in a local computer to determine the temperature, strain and residual stress of the product during fabrication. A feedback controller interfaces with the local computer and with a numerical controller and operates to control the material deposition process. The local numerical controller receives a file of a digitized description of the product from the remote computer, preferably via an Internet connection. The local computer sends temperature, strain and stress data to the remote computer, enabling a designer interfacing with the remote computer to monitor, control and modify the fabrication of the product in real time on line.