Industrial robotics modernizes and preserves a unique artisanal craft

L’Autre Instant is taking a new step in the modernization of its workshop by integrating a 5-axis robotic cell dedicated to machining wooden hat blocks. Supported by KUKA and 3IDM, the company combines the precision of industrial robotics with a rare artisanal expertise to gain greater design freedom, preserve its historical models, and ensure the long-term sustainability of its business.

In the world of premium hat making, every detail matters. Behind the creation of a hat lies an essential element: the wooden hat block on which the felt is shaped to achieve its final silhouette. This is precisely the craft of L’Autre Instant, a company founded by Mathieu Henra and his business partner Lucille Bac. Specializing in the design and manufacture of wooden hat blocks for the hat-making industry, the company preserves a particularly rare artisanal expertise, now threatened by the gradual disappearance of traditional hat block makers.

In this context, the challenge was clear: to modernize production capabilities while maintaining the quality standards and precision that define this exceptional craft.

A drive to push the boundaries of traditional machining

To manufacture its wooden hat blocks, L’Autre Instant initially relied on conventional 3-axis machining machines. Although this equipment met the company’s needs, it nevertheless limited the geometric complexity of the parts that could be produced.

Faced with growing demand for customization and the need for greater flexibility, Mathieu Henra wanted to take a new technological step by integrating a robotic solution capable of machining complex shapes in continuous five-axis motion.
The objective was not merely to automate production, but above all to provide greater creative freedom while maintaining the quality standards essential to this demanding market.

A robotic solution tailored to the industry's requirements

To meet this specific need, KUKA and 3IDM (Robotmaster distributor) supported the company in the integration of a 5-axis industrial robot dedicated to machining operations. Beyond the robot itself, the project also relies on 3IDM’s software expertise, enabling the company to fully leverage the capabilities of the installation.
This new solution enables:
• the machining of far more complex shapes;
• the maintenance of an exceptionally high level of precision;
• greater design flexibility;
• the modernization of a traditional craft without altering its essence.

We can adapt to different industries. In this case, we are talking about wood machining. For example, we can work with prototyping companies and architects, as well as support applications such as 3D printing, polishing, and painting.

Gilles Ferre, President of 3IDM

Different sizes and shapes of hat blocks

The power of digital technology serving craftsmanship

The integration of software solutions developed and distributed by 3IDM, such as Robotmaster, plays a key role in the success of the project. Thanks to advanced 3D modeling and simulation tools, machining programs can be validated beforehand, significantly reducing testing and setup times and enabling a satisfactory result to be achieved on the first attempt, without the need for physical testing.

Scanning technologies also make it possible to digitally scan and accurately reproduce existing models, a particularly valuable advantage in the luxury sector, where certain historical hat block designs must be preserved exactly as they are.
Meanwhile, App4PostPro simplifies the conversion of machining toolpaths into robotic movements, significantly streamlining the programming of the robotic cell.

Robotmaster software for 3D modeling, hat block design preparation, and simulation testing

For our customers, there is a final approval process, but we do not waste time with back-and-forth exchanges. With the internet, everything moves quickly now.

Mathieu Henra, Founder of l'Autre Instant

The cornerstone of this project lies in the ability to leverage data from the software environment already used by the customer. This approach made it possible to simplify integration, minimize the need for custom development, and significantly reduce the costs associated with the project.

Comprehensive support from design to commissioning

The success of the project also relies on the complementary expertise of KUKA’s teams, responsible for robotics expertise, and those of 3IDM, specialists in software, simulation, and technical support.

Thanks to this support, L’Autre Instant was able to carry out a large part of the integration independently, while benefiting from the assistance needed to quickly unlock the full potential of its new installation.

This collaboration demonstrates that even a niche artisanal business can now access advanced robotic technologies and integrate them effectively into its operations.

Results achieved

Thanks to the integration of the KUKA robot and Robotmaster software solutions, L’Autre Instant now benefits from:
• greater design freedom;
• the ability to produce more geometrically complex hat blocks;
• optimized programming times;
• the digital preservation of historical models;
• a modern production tool capable of supporting the company’s future growth.
Beyond the operational gains, this project demonstrates how robotics can help preserve and enhance exceptional craftsmanship by providing access to the most advanced technologies.

A concrete example of innovation supporting the preservation and transmission of craftsmanship

In a profession where the transmission of expertise is becoming increasingly challenging, automation does not replace the craftsperson. On the contrary, it provides new ways to express and enhance their expertise.
By combining the flexibility of a KUKA industrial robot, the digital tools of 3IDM, and the unique know-how of L’Autre Instant, this project demonstrates that tradition and innovation can move forward together, coexisting to ensure the long-term sustainability of a rare craft and prepare it for the future.