Abstract: Systems and methods are disclosed for contour crafting. The system includes a work tool configured to form a first layer by depositing material from a print head and following a path for depositing a second layer of material atop the first layer. The system further includes an optics assembly configured to produce a light pattern directed toward previously deposited material, and a camera configured to capture image data of the previously deposited material. The system further includes a processing device being configured to obtain, from the image data, a visible formation of the light pattern as it is projected onto the previously deposited material, and make a comparison of the visible formation to a predicted formation. The processing device is further configured to determine that the second layer is not aligned with the first layer, and adjust of the path being followed by the work tool based on the determination.

Abstract: A structural formation system includes a first component that is configured to deposit an unhardened first material for forming one or more layers of a three-dimensional structure. The structural formation system also includes a second component that is configured to at least partly incorporate a second material within the unhardened first material of the three-dimensional structure. Moreover, the first and second components of the structural formation system are independently operable for forming the three-dimensional structure integrally with the first and second materials.

Abstract: Systems and methods are disclosed for contour crafting. The system includes a work tool configured to form a first layer by depositing material from a print head and following a path for depositing a second layer of material atop the first layer. The system further includes an optics assembly configured to produce a light pattern directed toward previously deposited material, and a camera configured to capture image data of the previously deposited material. The system further includes a processing device being configured to obtain, from the image data, a visible formation of the light pattern as it is projected onto the previously deposited material, and make a comparison of the visible formation to a predicted formation. The processing device is further configured to determine that the second layer is not aligned with the first layer, and adjust of the path being followed by the work tool based on the determination.

Abstract: A structure is provided. The structure includes a first component disposed in the first plane. The structure also includes a second component extending from the first component and disposed in a second plane. The second plane is inclined at an angle with respect to the first plane. Each of the first component and the second component are constructed by forming layers parallel to each other using an additive manufacturing process.

Abstract: A computer-implemented method for selective tridimensional repair of a worn surface using at least a scanning device and an additive manufacturing device is provided. The computer-implemented method may include generating a worn surface model of the worn surface based on point cloud data obtained from the scanning device, superimposing the worn surface model onto a nominal surface model, generating trace data corresponding to dimensional variations between the worn surface model and the nominal surface model, and generating a rebuild volume based on the trace data.