THE 3D PRINTING SOLUTIONS COMPANY
A P P L I C AT I O N B R I E F :
FDM for Robotic End of Arm Tooling
OVERVIEW
Robots are used to perform tasks such as
sorting, transporting, palletizing, inspecting and
machining. A robot’s end of arm tool (EOAT),
also called an end-effector, is selected based on
the operation it will perform, such as gripping or
welding, and is specific to the part or tool that
the robot manipulates (Figures 1 and 2). Although
there are standard, off-the-shelf EOATs, robot
integrators and end-users often need customized
solutions to engage uniquely shaped objects,
optimize operations and improve productivity.
Because of the low-volume nature of custom
EOATs, many are machined from metal. They are
combined with stock components such as vacuum
cups, actuators, framing components and quick
changers. However, the time, cost and effort to
machine custom EOATs can be prohibitive, which
is why end-users may settle for non-customized,
stock solutions.
FDM IS A BEST FITSize:
• 25 mm (1 in) to 400 mm (16 in)
Quantity:
• 1 to 100s
Design:
• Complex/organic shapes
• Lightweight
Materials:
• Thermoplastics are acceptable
Tolerance:
• ≥ ± 0.13 mm (0.005 in)
Fabrication:
• In-house needed
Revisions:
• Frequent changes or replacements
S T R ATA S Y S . C O M
BENEFITS OF FDMAverage lead time savings:
• 70% - 85%
Average cost savings:
• 75% - 85%
Greater design freedom:
• Internal vacuum channels
• Consolidated assemblies
• Complex geometry
• Integrated components
Greater performance:
• Lightweight/low mass
• Optimized designs
• Impact dampening
• Non-marring
• Increased velocity
• Extended preventative maintenance cycles
Rapid response:
• In-house fabrication
• Redesign as needed
• Reduced downtime
Typical time and cost savings derived from numerous end-user analysis, testimonials and feedback. Actual savings may vary based upon numerous factors, including traditional time/cost, part geometry and utilized technology.
A P P L I C AT I O N B R I E F :
FDM for Robotic End of Arm Tooling
APPLICATION OUTLINE
FDM® technology provides an alternative
method for producing EOATs that can provide
dramatic time and cost savings while optimizing
performance. FDM is an additive manufacturing
(3D printing) process that builds plastic parts
layer by layer using data from 3D computer-aided
design (CAD) files. With FDM, EOATs can be
customized and tailored to a specific application
while often accelerating implementation on the
production floor.
FDM technology and materials make EOATs
that result in many performance advantages for
robots. FDM EOATs are lighter than those made
with metal, which means that robots can move
faster or carry larger payloads. Weight reduction
also improves motor efficiency and reduces
component wear, extending the time between
preventive maintenance (PM) cycles. FDM
technology easily makes hollow internal structures
and the thermoplastic materials are lightweight,
yet durable. When combined, weight reductions of
ninety percent or more are possible (Figure 3).
Plastics have two additional advantages: they
won’t scratch the products they grip, and they
dampen impact forces so that a tool crash is less
Figure 1: Pick-and-place robot with FDM gripper fingers (ABS-M30 Black).
Figure 2: EOAT for mechanically gripping a part (ABS-M30 Black).
Figure 3: Lightweight and impact-dampening EOAT made with FDM (ABS-M30 Black).
FDM FOR ROBOTIC END OF ARM TOOLING / 2
A P P L I C AT I O N B R I E F :
FDM for Robotic End of Arm Tooling
likely to damage the robot. An FDM EOAT can
also have components like magnets and sensors
embedded during the FDM build process. Fully
encased, the components are protected and won’t
mar the parts that come in contact with the EOAT.
FDM EOATs can be as simple or complex as
needed, which gives designers the freedom to
create tooling solely for its specific function. For
example, EOATs can have integrated vacuum
channels, assemblies consolidated to a single
part, or organic shapes that conform to the object
being manipulated by the robot (Figure 4). This
design flexibility provides a unique opportunity
to optimize robot performance and with FDM
technology, design complexity doesn’t increase
cost.
FDM EOAT manufacturing is responsive, efficient
and straightforward, turning EOAT design projects
into simple tasks. If a design needs to change,
FDM can produce a new tool in as little as one
day. New or revised designs and replacement
EOATs are delivered and mounted on the robot
quickly, regardless of complexity. During robot
testing and validation, a quick response avoids
delays in starting up a production line. Once FDM
EOATs are operating in production, rapid revisions
keep the line running at peak performance.
Figure 4: Integrated vacuum channels in the EOAT’s arms eliminated numerous external vacuum hoses (ABS Yellow).
Figure 5: Genesis Systems’ robotic waterjet cutter (ULTEM® 9085 resin Tan).
Figure 6: The Genesis FDM vacuum gripper has internal vacuum channels and weighs just three pounds (ULTEM 9085 resin Tan).
FDM FOR ROBOTIC END OF ARM TOOLING / 3
A P P L I C AT I O N B R I E F :
FDM for Robotic End of Arm Tooling
CUSTOMER STORY
Genesis Systems Group, headquartered in
Davenport, Iowa, designs, builds and implements
robotic tooling for work cells used in assembly
automation, material handling and processing, non-
destructive inspection and welding. One of Genesis’
specialties is building robotic, waterjet cutting
systems used to trim composite parts.
Genesis pioneered a safer approach for waterjet
cutting. Instead of using a robotic arm to move the
waterjet cutter, it keeps the waterjet fixed and uses
the robot to move the part (Figure 5). However,
this approach posed a challenge because each
unique part required a custom gripper to hold and
manipulate it. Genesis found that outsourcing for
CNC machined custom grippers was adequate but
each tool cost nearly $8,000 and took 20 days
to make.
For a better solution, Genesis turned to FDM for a
faster, lighter and less expensive EOAT to replace
conventionally fabricated metal grippers (Figure 6).
Engineers began by redesigning the EOAT to include
internal vacuum channels, which was cost prohibitive
with CNC machining. Using FDM simplified the
assembly and removed external vacuum hoses that
would be damaged during waterjet cutting. “FDM
grippers offer major advantages over metal grippers
and conventional fixtures. Using FDM gives us tools
that are quick, cheap, easy, durable and repeatable
for the waterjet application.” said Doug Huston,
process engineer for Genesis Systems Group.
The redesigned tool, made with lightweight FDM
plastic, also reduced the EOAT’s weight from 35
pounds to just 3 pounds. Huston noted that the
weight reduction made it possible to use smaller,
less expensive robots.
“Switching to FDM dramatically reduced the cost
of building grippers. Delivery time was substantially
reduced too, which is important because if a gripper
is destroyed in a crash, production may have to be
shut down until the replacement gripper is built.”
said Huston.
FDM FOR ROBOTIC END OF ARM TOOLING / 4
A P P L I C AT I O N B R I E F :
FDM for Robotic End of Arm Tooling
Application compatibility:
(0 – N/A, 1 – Low, 5 – High)
• FDM: Idea (3), Design (3), Production (5)
• PolyJet™: Design (3), Production (3)
Companion and reference materials:
• Technical application guide
− Document
• Application brief
− Document
• Video
− Commercial − Success story − How It’s Used
• Case study
− Genesis Systems Group − Robai Corporation
HOW DOES FDM COMPARE TO TRADITIONAL METHODS FOR GENESIS SYSTEMS GROUP?
METHOD TIME WEIGHT
CNC Machining 20 days 15.9 kg (35 lbs)
FDM 3 days 1.4 kg (3 lbs)
SAVINGS 17 days (85%) 14.5 kg (91%)
CANDIDATE PROFILE
Companies:
• Manufacturers, custom molders and foundries
• Robotic system integrators and accessory suppliers
Departments:
• Manufacturing, assembly
• Quality assurance
• Packaging and inventory control
Applications:
• Robot testing and validation
• Low, medium and high-volume production runs
Characteristics:
• Require custom EOAT solutions
• Want to optimize robot performance
• Need quick delivery or replacement
Traditional technology obstacles:
• Machining is cost or time prohibitive
• Machine shop is backlogged
• EOAT functionality limited by machining constraints
REPRESENTATIVE COMPANIES
FDM FOR ROBOTIC END OF ARM TOOLING / 5
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THE 3D PRINTING SOLUTIONS COMPANY
CONTACT:
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