Abstract: A method for forming a secondary component from an original component having an original shape includes separating the original component into a parent component and a replaced portion, and forming a replacement coupon using an additive manufacturing system. The replacement coupon is shaped to substantially match the original shape of the replaced portion. The method further includes coupling the replacement coupon to the parent component to form the secondary component. The method also includes at least one of (i) removing the replacement coupon from a build plate of the additive manufacturing system prior to application of any heat treatment to the as-built replacement coupon, wherein the replacement coupon maintains a near-net original shape of the replaced portion after removal, and (ii) entering the secondary component into normal duty with no hot isostatic press treatment of the replacement coupon having been performed.

Abstract: The present invention provides an apparatus for powder deposition mechanism in an additive manufacturing process. The apparatus comprises at least two belt driven cyclic arms which are configured to travel only in forward direction. The movement of the cyclic arm is such that a first arm is in movable position and a second arm is in stationary position simultaneously. A Programmable Logic Controller (PLC) controls the movement of the arm. At least one speed adjusting module is configured to adjust the speed of the cyclic arms. The speed adjusting module detects the limiting position of the cyclic arms. A vertical loop is configured to translate recoating arms in the vertical plane and horizontal plane. The vertical loop facilitates the automatic recoater arm changing mechanism.

Abstract: A method for forming a secondary component from an original component having an original shape includes separating the original component into a parent component and a replaced portion, and forming a replacement coupon using an additive manufacturing system. The replacement coupon is shaped to substantially match the original shape of the replaced portion. The method further includes coupling the replacement coupon to the parent component to form the secondary component. The method also includes at least one of (i) removing the replacement coupon from a build plate of the additive manufacturing system prior to application of any heat treatment to the as-built replacement coupon, wherein the replacement coupon maintains a near-net original shape of the replaced portion after removal, and (ii) entering the secondary component into normal duty with no hot isostatic press treatment of the replacement coupon having been performed.