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MX3D 3D-prints robot arm to show potential of generative design customization

MX3D has printed an optimized industrial robot arm, designed by engineers of Altair for a robot supplied by ABB.

This project is an application of large-scale 3D metal printing for heavy equipment parts with the goal to customize and optimize the robot arm for operational requirements and conditions. It shows the potential of generative design customization and a digital twin design approach to increase productivity for tailored robotic applications.

The stainless steel robot arm was fully 3D-printed using the company’s wire arc additive manufacturing (WAAM). This technology features advanced geometry processing, which allows complex organic geometries to be printed upright. Intelligent algorithms also determine the optimal printing strategy and toolpath direction for each geometry feature, helping to ensure the part is built up efficiently.

While the original part was 150 kg, the generative robot arm weighs only 73 kg. With 24/7 production, the print can be performed in four days. The part is finished by a standard 3-axis milling machine to achieve the right tolerances at the connecting points. After the successful print, the joint partners now intend to reassemble the complete robot.

The goal of the joint project was to enable the manufacturing of customized replacement parts. This allows for a rapid and automated production of large-scale parts that normally required extensive tooling and overseas production.

MX3D 3D-prints robot arm

MX3D has printed an optimized industrial robot arm, designed by engineers of Altair for a robot supplied by ABB.