According to one embodiment of the invention, a
system for fabricating a part includes a computer operable to control the fabrication of a three-dimensional part using a
solid CAD model, a deposition
station operable to deposit successive two-dimensional
layers of material to fabricate the three-dimensional part, and a
machining station operable to remove at least a portion of one or more of the deposited two-dimensional
layers of material. The deposition
station includes a substrate on which to fabricate the three-dimensional part, a
welding-based deposition
system having a
welding torch, a
laser-based deposition
system having a
laser head, a
plasma powder cladding system having 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. The
machining station includes a multi-axis milling
machine and an automatic tool changer. The milling
machine is 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.