3D printing with the robot: Manufacturing complex free-form parts without support material 

Additive manufacturing is considered a breakthrough and innovative technology with the potential to decouple industrial manufacturing from traditional production processes. In the Digital Factory at the FH Technikum Wien, research is currently being conducted into how 3D printing technology can be combined with the use of robots. The aim is to produce complex free-form parts without support material in this way.

Layer by layer

“Various additive manufacturing processes exist that are based on the same principle but use different materials,” explains Mohamed Aburaia, head of the Digital Manufacturing, Automation and Robotics competence field at the FH Technikum Wien. The fused filament fabrication process is the most commonly used due to its simplicity and low operating costs. In this process, a thermoplastic material (as a filament) is fed through an extruder, melted and applied to a build platform by the axis movements of an automated Cartesian system in such a way that a three-dimensional component is created layer by layer. However, the process also has drawbacks, as the components produced have mechanical and geometric limitations compared to other additive and conventional manufacturing technologies – such as tensile strength or the need for support material – and are often not suitable for functional applications.

More stable designs through the use of robots

The use of jointed-arm robots can offer a possible alternative here. Such systems with six or more degrees of freedom are used as standard manipulators in industry today. They offer the advantage of a compact but massive design and allow complex movements to be carried out. Compared to “classic” 3D printers, which are limited to three axes of motion, this allows printing in completely different axial directions – including horizontally, for example – which can be used to produce more stable designs. “Thanks to the enormous reach of these robotic systems, large and at the same time highly complex components can be produced in a cost-efficient and straightforward manner,” says Mohamed Aburaia.

Maximum precision with maximum reach

“The versatile possibilities of robot-assisted additive manufacturing are ideally suited to the high demands of industry,” the expert continues. With parts printed on site and exactly as required, there is no need for logistical effort and long supply chains. Extravagant designs and unusual structures can thus be created without restrictions.