Robotic 3D Manufacturing for Unmatched Flexibility

Jakarta, INTI - This article explores the rapidly growing field of robotic 3D manufacturing, highlighting its advantages in flexibility, reach, and efficiency over traditional methods.

Robotic additive manufacturing (AM) has taken significant strides in recent years. Technologies like robotic laser cladding, binder jetting, and laser hot-wire AM processes are making waves, particularly when combined with established welding techniques.

One such technique is robotic wire arc additive manufacturing (WAAM), which utilizes a robot equipped with a gas metal arc welding (GMAW) torch to melt wire into successive weld beads, building a freeform 3D shape layer by layer. Companies like Lincoln Electric are at the forefront of this technology, producing large metal parts for various industries.

Benefits of Robotic AM

• Greater Flexibility: Unlike traditional methods, robotic AM offers unmatched flexibility in terms of number of axes, torch accessibility, and scalability. Robots can be mounted on rails or pedestals to extend their reach, and positioners can be used to rotate or manipulate parts for optimal torch access. This eliminates the need for complex support structures, which reduces waste and production costs.
• Reduced Lead Times: Compared to traditional casting methods, robotic AM boasts significantly faster turnaround times. With AM, complex parts can be 3D printed in a matter of weeks, eliminating the need for lengthy mold design and iteration processes.
• Intr intricate Geometries: Robotic AM allows for the creation of complex geometries that would be impossible with traditional techniques. Additionally, it enables the integration of internal structures like cooling channels within parts.

Case Studies

• Lincoln Electric Additive Solutions demonstrates the power of robotic WAAM by producing large-scale parts like aerospace composite tooling facesheets, layup molds, functional metal prototypes, and complex parts for ships. Their use of SculptPrint™ OS CAD-to-path software streamlines the process by slicing the CAD model, determining ideal toolpaths, and optimizing process parameters for each layer.
• MX3D, a Dutch company, utilizes robotic WAAM to 3D print large-scale metal parts for heavy industry, including replacement parts for robots. This technology allows for rapid, on-demand production of parts that traditionally require extensive tooling and long lead times.

Robotic 3D Cutting

Robotic systems are not limited to additive manufacturing. They are also making their mark in 3D cutting applications. Companies like I-Cubed Industry Innovators Inc. leverage robots for various cutting tasks, including:

• Robotic Plasma Cutting: This technology offers fast, large-scale cutting capabilities for various materials, including steel and titanium alloys.
• Robotic Waterjet Cutting: Waterjet cutting utilizes a high-pressure stream of water, often mixed with abrasives, to slice through a wide range of materials with high precision. Robots bring six degrees of freedom to the waterjet cutting process, enabling intricate cuts at various angles.

Robotic 3D cutting involves complex programing to coordinate robot movements and part positioners. Offline programming (OLP) software eliminates the need for tedious point-by-point robot programming, streamlining the process.

The laborious process of composite layup, which involves stacking layers of carbon fiber prepreg material onto a mold, is being revolutionized by robotic automation. Researchers at the University of Southern California (USC) are developing human-robot collaborative cells to automate this process. These cells utilize robots and AI to handle sheet layup while human workers provide assistance in areas requiring dexterity or complex geometries.

Advantages of Robotic Layup

• Ergonomics: Robotic layup alleviates the ergonomic challenges associated with manual layup, which can lead to fatigue and injury.
• Consistency: Robots can ensure consistent quality from layer to layer, eliminating human error.
• Speed: Robotic layup has the potential to significantly increase production speeds compared to manual methods.
• Safety: Social distancing requirements due to the COVID-19 pandemic can be addressed by implementing robotic layup systems.

Robotic 3D manufacturing is rapidly transforming various industries. With its unmatched flexibility, robots are well-suited for the growing demand for customization and complex part geometries. As software, AI, and sensor technologies continue to advance, robotic 3D manufacturing is poised to revolutionize the future of production.*Hans