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.