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Additive manufacturing and 3D printing

3D printing production techniques, delivered by KUKA robots – A powerful combination of industrial robotics & automated toolpath generation software, that facilitate the efficient production of lightweight, low cost components from a wide variety of materials.

What is additive manufacturing and how does it work?

Additive manufacturing & 3D printing or industrial additive manufacturing, enables components of all different shapes, sizes and structures to be manufactured by the precise application of meltable material in layers in accordance with digital design data. 3D printing processes – including Selective Laser Melting (SLM) metal additive manufacturing; Fused Deposition Modeling (FDM) thermoplastic 3D printing; and Binder Jetting, a powder & binder 3D printing process – can be used, in particular, for the fast, precise and inexpensive production of workpiece prototypes or small series.

Tooling, automotive components, furniture and even construction: small & large ­format components made using automated 3D printing

Stable, lightweight, sustainable: 3D printing is proving to be an ideal production process in mitigating waste, reducing cost of entry and initiating flexible production methods. In the case of large format one-piece manufacturing, the reach of the KUKA industrial robot, ensures that even complex tool paths can be precisely executed. Even at a smaller scale, production runs can be undertaken quickly and cost efficiently, ideal for prototyping.


  • Aerospace

    Both lightweight and extremely robust: the versatile possibilities opened up by additive manufacturing are perfectly suited to the special demands of the aerospace sector.

  • Tier 1 Automotive industry

    Print-on-demand for more efficient automotive production: parts & tooling printed on-site and according to requirements eliminate long supply chains and logistical effort.

  • Academia / R&D

    3D printing applications are used in universities, research labs and innovation hubs to progress future manufacturing concepts & principles and advance rapid prototyping.

  • Plastics

    In the modern digital world, 3D printing is the most cost effective way of producing plastic parts without a mould, and continues to experience exponential growth.

KUKA Cell AM, from KUKA Systems UK Ltd.: pushing boundaries in industrial manufacturing.

Ai Build has mastered fully automated toolpath delivery for 3D printing, in partnership with KUKA

In harmony with the KUKA industrial robot, Ai Build make manufacturing faster, more predictable and highly repeatable.

AiSync: Developed for real world applications

AiSync additive manufacturing software, developed by Ai Build reduces failed builds by 65% and our users report a 90% efficiency gain in overall build time. Developed for real-world applications, AiSync accelerates and automates the creation of even the most advanced, multi-axis builds via an intuitive user interface.

With intelligent capabilities built in, such as collision detection, error detection and full build simulation, AiSync provides fast, efficient and predictable additive manufacturing.

Ai Build works very closely with partners in creating, designing, proving and implementing solutions. It has a fleet of contemporary KUKA robots in its laboratory.

  • Digital data

    Ai Build's intelligent AM platform replaces manual coding with visual programming, to completely simplify toolpath generation

  • Virtual modelling 

    A digital twin provides full visual build simulation and collision avoidance. *digital twin is a virtual model designed to reflect a physical object.

  • AiSync

    Equipped with powerful reporting and analytics, the entire 3D printing process is optimized and fully repeatable.

AiSync from AiBuild - The entire 3D printing process – monitored, controlled, measured and optimized

Additive manufacturing software for efficient, reliable and repeatable production, from KUKA Software partners AiBuild
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WAAM3D & KUKA: ideally positioned to meet the challenges of industrial additive manufacturing

KUKA's experience in the metalworking industry coupled with in-depth competency resources out of our system partner network positions us as experts in the delivery of small and large-scale additive manufacturing applications. A comprehensive range of industrial robots and tooling from some of the industry's leading suppliers of extruders enable us to meet the most important preconditions for the delivery of wire arc additive manufacturing (WAAM) solutions.

The manufacturing process of the future cannot rely on hardware from the past.

WAAM3D has developed state-of-the-art WAAM additive manufacturing technologies, in partnership with KUKA, that help their customers implement outstanding AM (additive manufacturing) solutions for large-scale industrial metal components. KUKA robots extend the spatial possibilities of 3D printing and open up new options for industrial production. WAAM3D have engineered the iconic orange industrial robot into their industrial additive manufacturing solution: RoboWAAM

 

 

From sensors to end-effectors and automation to health & safety, WAAM 3D put the user, at the core of our hardware design process.

How WAAM3D optimise component design and manufacture, to reduce material usage, production time, and overall cost.

WAAM3D, Milton Keynes and Aircraft Research Association Ltd (ARA), Bedford, have partnered to manufacture an aluminium nose cone of diameter 190mm and length 350mm. The component has been successfully integrated into a wind tunnel model ready to be tested in ARA’s own Transonic Wind Tunnel in the summer of 2022.

WAAM3D, Milton Keynes and Aircraft Research Association Ltd (ARA), Bedford, have partnered to manufacture an aluminium nose cone of diameter 190mm and length 350mm

3D metal printing allows complex geometries, large-format components and various materials from aluminum to titanium

At system partner Midwest Engineered Systems, KUKA robots demonstrate new areas of application in additive manufacturing with metal.

Optimal use of the versatility of plastics: support structures

The expert processing of a wide range of different plastics makes even highly complex or intricate designs possible: if required, specific combinations of materials, such as water-soluble plastic, can be used to make support structures onto which the actual building material is applied. Once printing has been carried out, the support structure can easily be removed – leaving the desired object exactly as specified.

Plastics have been one of KUKA’s core competencies for many years.

KUKA robots support 3D printing in many industries