Introduction
3DX Additive Manufacturing– helps you 3D design & print complex geometries, limitless shapes, and sizes using high-quality durable, and lightweight material.
BAO Packaging FZ LLC approached us with a challenge—how to produce a lightweight robotic gripper tool for and end-of-arm tooling system for their injection molder without compromising on strength or performance. In robotic automation tooling weight counts. A lighter tool means faster operation, reduced wear and tear, and lower energy consumption, all those factor contribute to increased efficiency and a reduced carbon footprint.
The objective was clear:
1. Design a lightweight, high-performance robotic gripper.
2. Manufacture it locally.
3DX Solution
We leveraged our expertise in reverse engineering, 3D printing, and digital manufacturing to design, prototype, and produce a next-generation robotic gripper using MJF technology with PA 12 material—a perfect combination for strength, flexibility, and durability.
Process
Reverse Engineering
To ensure a exact fit, we used:
1. Shining 3D Freescan Combo+ for an accurate 3D scanning of the mold.
2. Geomagic Design X to convert the scans into an accurate CAD reference model.
Designing
Using the scanned mold, we created a custom-fit robotic gripper designed to handle the required loads with minimal weight.
1. Design X allowed us to optimize the structure while maintaining tight tolerances.
2. The final model was exported to our build box preparation software for production.
Prototyping
Before full-scale production, we 3D-printed an initial prototype using PA 12 material on MJF technology, ensuring:
1. Precise fit with hoses, accessories, and threaded inserts.
2. Full functionality testing to validate performance.
Product & Optimisation
After successful testing, we refined the design to reduce the part count from 6 to just 3, simplifying assembly and improving efficiency.
1. MJF technology enabled support-free printing, giving designers more freedom.
2. Parts were printed, sandblasted, and prepared for final testing.
Testing & Implemention
The final robotic gripper was installed and tested for real-world performance:
1. Faster production with improved motion efficiency.
2. Digitally stored design, allowing BAO to manufacture on demand.
3. Significant weight reduction, optimizing energy efficiency and reducing robotic strain.
Result
By leveraging advanced 3D scanning, rapid prototyping, and MJF technology, we helped BAO achieve a fully functional, lightweight robotic gripper in just one week—ready for scalability and future automation needs.