Optimizing Additive Repair Processes with Polygonica: A Machine Works Application

AM software New Polygonica reference app for additive repair

2025-07-29 Source: Machine Works 1 min Reading Time

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With its latest reference application, Machine Works demonstrates how Polygonica can streamline additive repair processes. From mesh correction to toolpath generation, the software enables efficient restoration of worn components across demanding industrial applications.

A scan of a worn turbine blade (grey), with self-intersections (red), that requires healing and alignment with the CAD reference part (brown) (Source: Machine Works) — A scan of a worn turbine blade (grey), with self-intersections (red), that requires healing and alignment with the CAD reference part (brown)
(Source: Machine Works)

Software company Machine Works has released a new reference application that demonstrates how to generate additive repair paths using its Polygonica software library.

Polygonica is designed for working with polygon meshes and is used across various industrial sectors to address complex 2D and 3D geometric challenges.

The new example highlights a workflow relevant to additive repair processes, particularly in applications such as turbine blades, blisks, and aerofoils. Accurate registration and alignment of scan data is essential for modelling worn regions and preparing them for repair, including the identification and machining of rest-material for CAM tool path generation.

The demonstration includes automatic mesh repair from scanned data, alignment of the worn part with the original design, and calculation of smooth boundaries for the worn regions. It then generates a milling toolpath to clean the surface and an additive toolpath to restore missing material. The resulting toolpaths can be exported to a MachineWorks demo for visualization.

This reference app provides a practical insight into how Polygonica can support additive repair workflows with precision and efficiency.

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Date: 08.12.2025

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