In response to the automotive industry’s shift toward larger and heavier body panels, driven by megacasting and increased CFRP structures, Aibuild undertook a significant challenge. Tasked by a Global Automotive Brand, they sought to revolutionize the pick-and-placement process using 3D-printed polymer grippers produced in-house.

The existing gripper systems, reliant on standard metal struts, posed issues of high part count, weight, and cost as well as long lead times. The unique power of Aibuild’s software, integrated with a multi-axis printer, allowed for the creation of complex structures without support, reducing time and waste.

Different Layer Types

For assigning different printing parameters

Cantilever analysis

to assign variable thickness for capping

Simulation

to check the robot motions before print

The results have been remarkable, with the 3D-printed gripper surpassing 100,000 cycles, delivering a 50% reduction in cost, halved lead times, up to 5% energy savings per robotic arm, and the ability to use lower payload robots, contributing to substantial energy savings.

All materials used are recyclable, aligning with a sustainable and circular manufacturing approach. This innovative solution not only addresses current challenges but also presents a transformative opportunity for automotive manufacturers globally.

Aibuild AM Software vs. Traditional Slicers

Traditional 3D printing slicers often offer horizontal slicing, leading to rough and inaccurate surface finishes and necessitating support structures for cantilevering areas. This approach results in material waste, extended printing times, and the need for post-processing.

In contrast, Aibuild technology revolutionizes the slicing process. It follows the geometry normals, employing multiplanar slicing with variable layer heights and extrusion rates which are calculated automatically per material type and machine specifications. This not only ensures more precise surface finishes but also leverages the freedom of axis provided by robotic arms. The innovative printing strategy eliminates the need for support structures and allows for capping in cantilevering areas.

Moreover, Aibuild enables the creation of infills with variable density, allowing for solid or high-density patterns only where structurally necessary. This intelligent approach conserves material, reduces printing time, and produces lighter weight parts, showcasing the efficiency and versatility of Aibuild technology in additive manufacturing.