激光熔覆成形高性能薄壁金属零件时，由于熔覆层凹凸不平和挂渣导致成形件表面精度差，甚至后续成形困难，往往需要在成形过程中或成形后辅助机械铣削加工和抛光处理。但是成形件因急冷凝固，表面硬度很高，加工非常困难；形状复杂的零件机械加工更需多次装夹，加工时间长，有时要占整个制造周期的60% 以上。为此提出了一种基于激光铣削的光内送粉激光熔覆复合精确快速成形新方法，采用激光铣削对激光熔覆成形件进行熔覆层的精密整形，该方法相比于传统的激光熔覆大大提高了成形件表面的成形质量，从而实现薄壁金属零件的精确成形。该方案避免了可能需要的机械精整加工，缩短了加工时间，降低了加工成本。

The forming of thin-walled parts by laser cladding results in creation of uneven cladding layers that manifests itself in poor surface. Furthermore, it makes follow-up forming difficult. In this case, it becomes necessary to conduct auxiliary mechanical milling and polishing. However, laser forming is one quench solidification process that results in high hardness which makes machining of these hardened surfaces impractical. In addition, if the shape of parts is complex, the finishing machining operations will require multiple jigs and fixture setups which are time consuming and highly inefficient. In fact, the finishing machining operations can account for more than 60% of the entire manufacturing cycle. To overcome the difficulty, a new composite precision rapid prototyping method is proposed. This new method is based on machining the cladding part by laser milling. The proposed high performance and precise approach results in greatly improved surface quality, as measured by surface morphology, as opposed to the traditional laser cladding forming. Furthermore, it will eliminate the need for the post processing and reduce the processing time and ultimately the processing cost of the part.