Abstract: A method of determining a tool path for an additive deposition on a surface, the method including receiving primary edges data of the surface of a three-dimensional (3D) object; calculating a number of raster lines for applying an additive deposition on the surface; mapping a raster pattern to the surface of the 3D object; calculating surface normal and rotational angles along the raster lines; calculating a nozzle velocity of an additive application used for producing the additive deposition on the surface; identifying curvature effects of the 3D object; and establishing an order of performing passes of the additive deposition on the surface based on a selected direction for performing the additive deposition and a consideration of a residual stress profile of a resulting deposit.

Abstract: A system and method for controlling cold spray deposit adhesion for induced release of a deposit from a substrate includes tuning a material surface condition of a substrate used to support a build of a cold spray material to a level proportionate with deposition conditions of the cold spray material for adhesion to the substrate; selecting an impact velocity for deposition of the cold spray material to be substantially equal to or greater than a critical velocity for adhesion of the cold spray material to the substrate; depositing the cold spray material on the substrate to form a deposit; and releasing the deposit from the substrate without permanently damaging the substrate to allow for reuse of the substrate for a subsequent cold spray deposition process.