Patent ID: 8192792

Claim:
A method of applying an abradable material onto a seal backing material surface comprising: measuring a seal area on the seal backing material surface; selecting at least one abradable material for the seal area; deriving a nozzle path from a surface of said seal backing material across said seal area; said deriving step comprising deriving said nozzle path as a function of the selected at least one abradable material and a desired porosity; deriving a spray distance for a spray nozzle along said nozzle path so as to maintain said spray nozzle at a constant distance from a surface of the deposited at least one abradable material and not from the surface of said seal backing material; and depositing said at least one abradable material from said spray nozzle onto said seal backing material surface so that said at least one abradable material plastically deforms without melting and bond to said seal backing material surface upon impact with said surface.