LASER MARKER ROBOT END ARM

CUSTOMER - PROMETAL3D

Prometal3D is a company that specializes in precision machining and providing rapid prototyping services and short-run series using 3D printing technology with HP Jet Fusion 3D 4200 Printing Solutions. Prometal3D’s activities are focused on engineering and mechanic production

One of Prometal3D’s main customers and partners is AIRA Robotics, a robotics production company whose main business relates to robot design and production for food-processing lines. These robots are composed of a large number of mainly metallic parts.

One of the features of these robots is an end arm that is assembled using metallic parts and aids in laser-marking products on the foodprocessing line.

CHALLENGE AND RESULTS

The laser marker robot must move the laser head (end arm) precisely and quickly in order to accelerate processes as much as possible. AIRA asked metallic parts producer Prometal3D to improve the laser head design in order to reduce the part’s weight and improve performance

Prometal3D suggested transforming the laser head’s parts from metallic to plastic parts using HP Multi Jet Fusion technology and HP 3D HR PA 12 GB. When the transformation was complete, they achieved a 75% weight reduction, which allows for the use of smaller robots instead of the current larger and more expensive robots. This change also results in increased free space on the food-processing line and less energy consumption.

INDUSTRY SEGMENT: PARTS PROVIDERS | CNC Manufacturers

APPLICATION VERTICAL: INDUSTRIAL | Robots

FINAL PART: Short runs

LEGACY SOLUTION

ASSEMBLY

25 CNC Machined and welded metallic parts made of stainless steel and aluminum.

PRODUCTION TIME

Three weeks

WEIGHT

35 kg

HP MJF SOLUTION

ASSEMBLY

10 3D printed parts made with HP 3D HR PA 12 GB

PRODUCTION TIME

Five days
76% Production time reduction

WEIGHT

5.8 kg
83.5% Weight reduction

MATERIAL

HP 3D HR PA 12 GB

POST-PROCESSING

Bead blasting with stainless steel spheres

HP MJF BENEFITS

  • Increased productivity
  • Weight reduction without compromising part strength

HP 3D HR PA 12 GB BENEFITS

  • Best isotropy, robustness, and general performance compared with other 3D printing materials
  • Dimensional accuracy: Thanks to the high accuracy1 delivered by HP 3D HR PA 12 GB, bearings and mechanical elements can be easily assembled with the 3D printed parts without any additional mechanical processing.

DESIGN IMPROVEMENTS

Each new part design for 3D printing integrates rounded edges with a specific radius. This feature is an important requirement for meeting hygienic standards in food processing plants. CNC Machined parts had squared (90º-angle) edges, which is a problem for dirt accumulation in the edges as it is very difficult to clean and remove dirt.

The manufacturer had not been applying this rounded-edge feature in CNC Machined designs because it would cause a 15% cost increase and up to an extra week of manufacturing time.

OVERALL SAVINGS

Thanks to the robot end arm weight reduction, Prometal3D’s customer (AIRA Robotics) was able to apply this new design in a model for smaller robots, reducing overall costs of their projects, logistics, installation, energy consumption, and also space required in factories, production centers, and food processing plants.

Each robot used to cost to AIRA Robotics customers around 50.000€ ($57,600) per robot. Thanks to this optimization, the new robot models are smaller and cost approximately 40.000€ ($46,100).

In a food processing plant, there can be at least 10 robots (depending on plant dimensions), which implies a direct cost reduction of at least 100.000€ ($115,116), not including other types of cost reductions and benefits.


VIEW THE PRINTERS USED

HP Jet Fusion 3D  300/500 Printers
HP Jet Fusion 3D 4210/4200
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