Transforming Production: Industrial Robots and the Evolution of 3D Printing

Transforming Production: Industrial Robots and the Evolution of 3D Printing

Industrial robots are multitasking machines with high repeatability and reliability that have transformed the way products have been manufactured over the past 60 years. ^[1] Originally dominant in the automotive industry, these versatile machines have spread to many other sectors, such as electronics and semiconductors, healthcare and medicine, food and beverage, pharmaceuticals, aerospace, and defense and security among others. ^[2] the flexibility of robots to multitask has opened the doors to enthusiasts and industries to adapt this technology to other sectors, such as 3D printing, allowing for customized, lightweight parts for fast-functional prototyping and end-use production. ^[3]

Commercial Techniques in 3D Printing

3D printing is a process of creating three-dimensional solid objects layer by layer with the support of a visual design. The type of material and process used for 3D printing determines in great measure the configuration of the printer. Not all 3D printer configurations resemble robotic arms; instead, they often appear to be complex, specialized, and high-end equipment comparable to CNC machines that focuses exclusively on one specific method of 3D printing. The most prevalent commercially available types of 3D printing in the market include:

1) Material Extrusion (MEX): This technique involves extruding a thermoplastic filament through a heated nozzle, laying down the material layer by layer. ^[4],

2) Stereolithography (SLA): In this process, a vat of liquid photopolymer resin is solidified layer by layer by a UV laser, allowing for precise detailing. ^[5], and

3) Selective Laser Sintering (SLS): This method uses a laser to selectively fuse powdered material, binding the particles together to form a solid structure typically made from nylon, polyamide or metal, eliminating the need for additional support material. ^[6]

Benefits of 3D Printing in Industry

3D printing is currently attracting the attention of enthusiastic engineers and researchers in the industrial sector due to its ability to 3D print in batches and its noticeable improvements in minimizing printing time and waste material over the past few years. These interests have pushed 3D printing companies to tackle significant technological challenges in creating better 3D printers that can produce parts faster and test them under extreme conditions.  

Unlike the systematic process of manufacturing individual components or assemblies (such as: machining, molding, casting, forming, etc.), which may require specialized knowledge and a considerable manufacturing time, 3D printing allows for immediate production with minimal engineering knowledge by translating digital designs into physical objects through the layering of materials. Ultimately, 3D printing enables manufacturers to produce customized parts on demand, without the constraints of investing in expensive machines, labor, tools and components that can only be used for a single purpose. ^[3] Furthermore, 3D printing enables fast production of replacement of spare parts to reduce downtime, ensure continued operation, lower inventory costs, enhance overall efficiency, and minimize disruption, especially when key components are not available or no longer manufactured in the market. ^[3]

Overall, Parts typically account for 20 to 30% of a company’s total inventory expenses. ^[7] With the implementation of 3D printing, many companies could see a reduction in these costs, freeing up space for digitally stored parts that can be easily modified. This shift not only cuts expenses but also opens up new possibilities for innovation and product improvement. ^[8]

The Role of Robotic Arms in 3D Printing

In general, articulated robots usually possess the capability to perform multiple tasks simultaneously, be reprogrammable, multi-purpose and work collaboratively with other machinery, robots and operators. ^[9,10] Currently, there are diverse robotic applications capable of producing large-scale 3D printed parts by depositing materials layer by layer, using thermoplastics, metalwork, and construction materials. ^[11,12,13] Each of these robotic applications requires different robot configurations (degrees of freedom (DOF), joint angles and positions, kinematics, workspace, etc.), depending on the type of material, orientation of the tool, and workspace.

Challenges in 3D Printing

One of the most significant challenges for 3D printers today involves producing parts with complex geometries that are usually difficult to manufacture, even with multi-axes CNCs. These types of parts, such as turbines or jet engines, operate under extreme conditions, including high temperatures and pressures. ^[11] For these parts to be reliable, safe, and effective, the materials employed must maintain consistent properties despite the diverse tasks and environments. These consistent properties can only be achieved by analyzing the internal structures formed through 3D printing to mitigate risks of unexpected failures, such as fractures, and to resolve aesthetic issues like rough surfaces and wear. Rigorous inspections and certifications are essential to uphold the quality and safety of these printed components in the near future, facilitating the transition from rapid rapid prototyping to rapid production.

Future Directions in 3D Printing

As we look towards the horizon of 3D printing technology, one of the most promising advancements is the integration of Directed Energy Deposition (DED). DED is a technology that is attracting attention by combining industrial robots and 3D printing. This technology involves delivering material, such as powder or wire, to the focal point of a high-powered energy source (i.e., laser, electron beam, or plasma arc) to feed continuously melting of material. ^[14,15]

The laser melts the material and deposits it onto previous layers or a substrate, creating a welding pool that solidifies into the base material. This process forms a metallurgical bond that builds up the structure of the 3D-printed part, layer by layer. Overall, DED allows for great flexibility in material composition and can be used for multi-material parts, requiring sophisticated control of the energy source, feedstock, and movement to ensure proper deposition and bonding. ^[16]

With DED technology, it is possible to: 1) repair and augment components on existing parts using a substrate as the base 2) create new parts with complex geometry, and 3) use multiple materials in a single build, making it suitable for aerospace, automotive, and medical industries.

Overall, DED can produce large geometries, create fine features, apply precise amounts of material, perform repairs, and multi-material applications. ^[17]

Similarly, robotic DED, like material extrusion, can execute complex trajectories. By controlling the tool’s orientation and the amount of material dispensed, robots are enabled to 3D print without support material, even under challenging conditions.  

If you have any questions about how 3D printing can be tailored to meet the specific needs of your industry, please don’t hesitate to contact us at ITR Solutions. We’re here to help you navigate the possibilities and integrate cutting-edge 3D printing technologies to achieve applications with high accuracy and control into your operations.

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If you have any questions about how 3D printing can be tailored to meet the specific needs of your industry, please don’t hesitate to contact us at ITR Solutions. We’re here to help you navigate the possibilities and integrate cutting-edge 3D printing technologies to achieve applications with high accuracy and control into your operations.

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References

[1] Miller RK. Industrial robot handbook. Springer Science & Business Media; 2013 Nov 21.

[2] Hunt VD. Robotics sourcebook. Elsevier; 2012 Dec 2.  

[3] How robotics and automation can benefit from 3D printing, explains Replique.  

[4] Gibson I, Rosen D, Stucker B, Khorasani M, Gibson I, Rosen D, Stucker B, Khorasani M. Material extrusion. Additive Manufacturing Technologies. 2021:171-201.  

[5] Kafle A, Luis E, Silwal R, Pan HM, Shrestha PL, Bastola AK. 3D/4D printing of polymers: fused deposition modelling (FDM), selective laser sintering (SLS), and stereolithography (SLA). Polymers. 2021 Sep 15;13(18):3101.  

[6] Kumar MB, Sathiya P, Varatharajulu M. Selective laser sintering. Advances in Additive Manufacturing Processes; China Bentham Books: Beijing, China. 2021 Nov 29:28.  

[7] NETSTOCK. Inventory Holding Costs: How to Calculate and Reduce [Internet]. (US); [reviewed 2024 Sept 1; cited 2024 Sept 9]. Available from: https://www.netstock.com/blog/inventory-holding-costs-how-to-calculate-and-reduce/.

[8] How 3D Printing Will Change Supply Chains and Improve Sustainability.  

[9] Spong MW, Hutchinson S, Vidyasagar M. Robot modeling and control. John Wiley & Sons; 2020 Mar 30.  

[10] Bragança S, Costa E, Castellucci I, Arezes PM. A brief overview of the use of collaborative robots in industry 4.0: Human role and safety. Occupational and environmental safety and health. 2019 Feb 28:641-50.

[11] Badarinath R, Prabhu V. Integration and evaluation of robotic fused filament fabrication system. Additive Manufacturing. 2021 May 1;41:101951.  

[12] Puzatova A, Shakor P, Laghi V, Dmitrieva M. Large-scale 3D printing for construction application by means of robotic arm and Gantry 3D Printer: A Review. Buildings. 2022 Nov 18;12(11):2023.

[13] KUKA. 3D metal printing without supporting structures [Internet]. Shelby Parkway, Mi (US); [reviewed 2024 July 28; cited 2024 Sept 9]. Available from: https://www.kuka.com/en-us/industries/solutions-database/2024/03/hs-automation-3d-metal-printing.

[14] Murr LE, Johnson WL. 3D metal droplet printing development and advanced materials additive manufacturing. Journal of Materials Research and Technology. 2017 Jan 1;6(1):77-89.

[15] 3Dnatives your source for 3D printing. The Complete Guide to Directed Energy Deposition (DED) in 3D printing [Internet]. Danbury, CT (US); [reviewed 2024 Aug 1; cited 2024 Sept 8]. Available from: https://www.3dnatives.com/en/directed-energy-deposition-ded-3d-printing-guide-100920194/

[16] Svetlizky D, Das M, Zheng B, Vyatskikh AL, Bose S, Bandyopadhyay A, Schoenung JM, Lavernia EJ, Eliaz N. Directed energy deposition (DED) additive manufacturing: Physical characteristics, defects, challenges and applications. Materials Today. 2021 Oct 1;49:271-95.

[17] Ahn DG. Directed energy deposition (DED) process: state of the art. International Journal of Precision Engineering and Manufacturing-Green Technology. 2021 Mar;8(2):703-42.