Patent ID: 7020539

Claim:
A system for fabricating a part, comprising: a computer operable to control the fabrication of a three-dimensional part using digital engineering data; a deposition station operable to deposit successive two-dimensional layers of material to fabricate the three-dimensional part, the deposition station comprising: a substrate on which to fabricate the three-dimensional part; a welding-based deposition system comprising a welding torch; a laser-based deposition system comprising; a laser head; and a powder delivery system comprising a hopper adapted to contain a powder and continuously feed the powder through an output of the hopper, a metering device adjacent the output of the hopper adapted to receive the powder continuously fed through the output of the hopper, and a vacuum powder removal device operable to remove the powder from the top surface via a vacuum; a plasma powder cladding system comprising a plasma torch; and a multi-axis robot operable to, when directed by the computer, utilize one of the welding-based deposition system, laser-based deposition system, and plasma powder cladding system to deposit any of the two-dimensional layers of material; and a machining station operable to remove at least a portion of one or more of the deposited two-dimensional layers of material, the machining station comprising: a multi-axis milling machine; and an automatic tool changer associated with the milling machine, the milling machine operable to, when directed by the computer, select from a plurality of machining tools associated with the automatic tool changer for use in the milling machine.