FEATURE Modern materials
In this article, Nick Dinges, Chief
I
n the ever-evolving landscape of production and logistics, robotics & automation play an increasingly vital role, driven by the wave of digitisation.
However, as with any technology, there are also hurdles which have to be overcome, especially when it comes to the production of customised manner. This is where 3D printing steps in. Before exploring the connection with
robotics, it’s important to understand 3D printing technology, also known as additive manufacturing. Additive manufacturing enables the conversion of digital designs into tangible objects by building up layers of material. Production can start smoothly only when the right design is in place, eliminating the need for a huge production ramp-up. This freedom enables intricate designs, rapid prototyping, and on-demand production of manufacturing landscape.
Robotics is one of the industries where the And there are many reasons for it. One is the possibility to create custom parts of robotics and automation machinery using 3D printing. Traditional manufacturing methods often fall short when it comes to creating parts, such incurring exorbitant costs due to the creation of specialised tools and moulds. Thanks to 3D printing, even small players (w), can use 3D printing to create budget-friendly robot parts, as there is no minimum order quantity, meaning parts can be produced starting from lot-size one. Weight is a critical factor in optimising
robotic performance. Traditional manufacturing often results in excess weight due to subtractive processes. 3D printing revolutionises this by allowing engineers to design intricate, hollow structures, optimising weight without compromising strength. This exoskeletons, and various robotic systems. consolidation of multiple parts into a single, complex structure. This not only reduces overall weight but also minimises assembly challenges and inventory complexity. On the other side, 3D printing allows the separation
32 June 2025 | Automation
3D PRINTING’S ROLE IN ROBOTICS The intersection of 3D printing
and robotics reshapes how we conceive, design, and build robotic systems
3D PRINTING’S ROLE IN ROBOTICS
of a single part into distinct components, Compared to traditional methods, 3D prototyping and design alterations. Engineers and designers can swiftly translate conceptual ideas into tangible prototypes. This means they can test a prototype out almost they want to tweak or change the design, of 3D printing, empowering innovators to adapt and optimise robotic components with unprecedented speed. This not only accelerates the product development cycle and reduces time-to-market considerably, but also fosters a culture of continuous The wear and tear faced by robotics and automation machinery can lead to costly downtime. Traditional methods of obtaining spare parts involve a time-consuming process of ordering, shipping, and, in some cases, custom manufacturing. 3D printing provides a rapid and cost- production of spare parts, just on-demand. Instead of waiting for shipments or relying on extensive inventories, robots can be quickly restored to operational status with 3D-printed minimises downtime, ensuring continuous robot functionality. Grippers, in particular, are undergoing a
revolution thanks to additive manufacturing. It enables the creation of grippers in small
but also lightweight and optimised. When the need arises to change grippers, 3D printing facilitates a swift process with short development and production times. This capability translates into faster movements, reduced cycle times, and an overall more agile manufacturing process. In a recent cooperation with
struktur.form. design Engineering GmbH for example, we were able to reduce the weight of a cobot gripper by 78%, part count by 84% and overall production cost savings by 30%, just via redesign and production via additive manufacturing. Beyond these core connections, the collaboration between 3D printing and example, embedding sensors and electronic components directly into robotic structures using 3D printing enhances their functionality and streamlines assembly processes. Moreover, 3D printing serves as a catalyst for innovation and education in robotics. It fosters creativity among students and researchers, accelerating the learning curve and driving advancements in the development of robotic systems. The marriage of robotics and 3D printing can even extend beyond conventional roles. Here, robots themselves become integral 3D printers, amplifying the scope and scale of additive manufacturing.
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