Innovation & R&D18 November 2020

Kuka Robot 3D Printing Integration: Large-Format Additive at Research Scale

Integrating Noztek extrusion technology with 6-axis robotic arms opens large-format, non-planar 3D printing capabilities that fixed-axis desktop printers cannot achieve.

Beyond the Cartesian Printer

Conventional FFF 3D printers operate in three orthogonal axes. This constraint shapes everything about how parts are designed for additive manufacturing: layer orientation, support structure requirements, and the anisotropic mechanical properties that result from planar layer stacking. 6-axis industrial robots are not constrained to planar motion. A robotic extrusion head can follow a curved surface, deposit material along the principal stress directions of a component, and print without the planar layer interfaces that concentrate failure initiation sites in conventional FFF parts.

The Integration Challenge

Attaching an extrusion head to a robot arm is mechanically straightforward. The challenges are in the software and materials systems. Robotic motion planning for non-planar deposition requires path planning tools that go significantly beyond standard slicer software. The extrusion rate must be synchronised with the robot's end-effector speed to maintain consistent material deposition.

Custom filament produced on desktop extrusion equipment addresses the material side of this integration. The specific diameter tolerances, melt viscosity, and mechanical properties required for robotic extrusion heads often differ from standard commercial filament specifications. Producing custom filament allows the material to be matched to the process rather than vice versa.

Non-planar printing along principal stress directions can improve the in-plane/out-of-plane strength ratio of FFF parts dramatically. For structural components in robotics, automotive, and aerospace applications, this capability changes the relevance of FFF from "prototype and appearance model" to "structural component" territory.

Material Requirements for Robotic Extrusion

Robotic extrusion for structural applications favours materials with good melt strength, consistent viscosity, and mechanical properties suited to the application loading. Carbon fibre reinforced nylon and carbon fibre reinforced PEEK are both active areas for robotic extrusion research. The Noztek extrusion platform provides the precise, documented process control needed to produce research-grade filament for robotic extrusion development.