The OSCAR WeldingCell is a turnkey, configurable robotic cell for laser metal deposition, repair, coating and additive manufacturing.

It combines the ProFocus laser system with an industrial robot, a tilt-and-turn positioner, a component scanner and digital toolpath planning in an integrated solution. While ProFocus provides the welding technology, the WeldingCell also includes the motion, scanning and cell equipment required for automated processing.

The OSCAR WeldingCell is suitable for restoring worn component areas, applying functional coatings and additively manufacturing metal structures and components.

The scanner, robot and positioner are particularly useful for processing complex contours and recurring tasks. The component dimensions, weights and geometries that can be accommodated depend on the specific cell configuration. The suitability of the base material, filler material and processing strategy is assessed for each application and can be evaluated through a feasibility study.

The ProFocus process control system uses coordinated assistance functions to manage the interaction between energy input, wire feed and working distance. StartControl enables automatic start-point detection and coordinated start-stop sequences. WireWatcher monitors the wire process to help prevent uncontrolled wire break-offs. HeightControl regulates the working distance and supports consistent layer build-up.

Additional functions include anti-balling and anti-sticking assistance, camera-based process observation, component temperature monitoring and process data logging. The specific range of functions is defined during system configuration.

A laser scanner first captures the existing component geometry. The scan data is used to generate a point cloud, which forms the basis for CAD/CAM-based process planning. Suitable deposition toolpaths are then generated and executed by the robotic system using the ProFocus process head. The tilt-and-turn positioner helps orient the component for processing. Connecting these steps digitally reduces manual data transfers and makes recurring tasks easier to prepare. The level of automation is tailored to the application and cell configuration.

The OSCAR WeldingCell reduces manual tasks through a digitally connected process chain covering component scanning, data processing, toolpath planning and automated laser metal deposition.

Targeted, near-net-shape material deposition can reduce filler material consumption and subsequent machining requirements. For high-value components, repairing worn areas also allows the existing part to remain in use. The achievable savings depend on the application, the previous manufacturing or repair method and equipment utilisation.