Design and Implementation of 3D Scanning Technology For Tooling Repair In Hybrid Manufacturing Processes

Forging tools are critical components in manufacturing but suffer from short lifespans due to extreme thermal and mechanical stresses, leading to high replacement and repair costs. Traditional repair methods, such as welding and re-profiling, are labor-intensive, hazardous, and prone to inconsistencies. This research investigates the integration of 3D laser scanning technology into a hybrid manufacturing process—combining Directed Energy Deposition (DED) and subtractive machining—for repairing H13 tool steel forging dies. The study demonstrates how high-precision 3D scanning enables accurate damage assessment, repair planning, and dimensional verification. A custom scanner assembly incorporating the Zeiss Atos Q was designed to operate within the RPMI 222XR DED system under an inert argon environment. Experimental results validate the scanner’s accuracy across multiple environments, with deviations remaining within ±0.09 mm. Material characterization of repaired specimens revealed uniform hardness values (545–616 HV) and microstructural integrity comparable to the original tool steel, confirming effective restoration. The proposed methodology reduces lead times, improves repair accuracy, and restores mechanical properties, offering a scalable, automated alternative to conventional repair techniques. This work contributes to advancing hybrid manufacturing for high-value tooling applications, emphasizing precision, automation, and material integrity.