Patent ID: 7342195

Claim:
A customizable ion fusion formation system for three-dimensional repair of a workpiece with successive layers of feedstock material comprising: a deposition head operable to emit a plasma stream in a plasma path by energizing a flowing gas and to feed feedstock into the plasma path of the plasma torch, the feedstock melting at a deposition point when introduced into the plasma path; a positioning arm, the deposition head mounted to the positioning arm; a moveable positioning platform, the positioning arm mounted to the moveable positioning platform; and a control platform, the control platform positioned separate and apart from the moveable positioning platform and including a plurality of control components for controlling the position of the positioning arm and operation of the deposition head, whereby the moveable positioning platform is moveable to position the positioning arm along an X, Y, and Z axis, thereby aligning the deposition head with the workpiece to repair the workpiece by transferring the feedstock from the feedstock feeder in a controlled manner by melting the feedstock at the deposition point and allowing it to re-solidify on the workpiece or on previously-deposited feedstock material.