Robots are increasingly beneficial for additive manufacturing, improving efficiency, precision, and part size. In this evolving field, both long-standing industry leaders and startups can leverage robotics to enhance additive manufacturing outcomes.

Two companies manufacturing single-piece components with robotic assistance are the Silicon Valley startup Arevo and the largest robot manufacturer in America, FANUC, as well as a division of Japan's FANUC. These are two of the many companies innovating in this field, dedicated to producing larger parts and eliminating weak joints.

In contrast, the German company Physik Instrumente, headquartered in Auburn, Massachusetts, USA, has conducted in-depth research on the sub-micron precision of its parts, which in turn enables additive manufacturers to achieve higher precision in their additive manufacturing processes.

Maximize automation from the start

Launched as a startup in 2013, Arevo has developed direct digital technology to manufacture robust, lightweight parts according to a range of customer requirements. Wiener Mondesir, co-founder and CTO of the Silicon Valley company, described its proprietary technology.

Xplorator software can create lightweight carbon fiber composites. His partners, other startup veterans, agree with his view that "if we have software that can examine actual load conditions and propose solutions, that software will truly unlock much of what we can do with correct fiber orientation."

Xplorator opened the door to the founder's second goal, which is to eliminate manually crafted programs. Mondesir stated, "There must be an automated method to give you freedom."

He said that in 2014, patents were expiring and the manufacturer movement was underway. The next step for Arevo is to use software modeling to find the optimal build method. 3D printing is key to constructing composite structures. "If we customize it using software, we will be able to understand how to orient the fibers and how to build structures that meet any predetermined material or part properties. Therefore, we built a machine that can basically do this." The latest iteration is the Aqua 2 carbon fiber printer.

Surface finish after post-processing

Mondesir stated that the third most important aspect for the development of Arevo is its materials. 3D printing was initially used for prototypes, but the current goal is to print components for production. "In production, it is necessary to understand how the part performs in the real world in terms of quality, consistent repeatability, accuracy, dimensional tolerances, and quality assurance. Therefore, we need to address a process issue." He said, "As a startup, there is a lot to take on at once." "We are ambitious and have decided to control our own destiny," from design to production.

After Arevo created the first prototype, it added ABB robots to provide multi-axis access and 3D spatial orientation capabilities. Arevo's use of carbon fiber composites enabled a short transition time from conceptual product to functional product. Its industrial-grade continuous fiber 3D printing system can print parts up to one cubic meter in size.

Success all the way

Arevo accepts orders for customer-ordered parts and continues to develop new applications for carbon fiber composites, hosting a hackathon every month. Through these hackathons, it has developed popular continuous carbon fiber tennis rackets and furniture. In a separate initiative, Arevo developed the carbon fiber bicycle Superstrata this year, which started as a technology and product demonstration but also has an exciting market. Its frame is monolithic carbon fiber, designed by Arevo's Xplorator and printed on its Aqua platform. Each bicycle is customized to accommodate different leg lengths and body sizes.

Arevo expanded its printing capacity from 5 Aqua machines at its Milpitas, California farm by adding 15 Aqua machines at a new farm in Vietnam. The Vietnam farm is planned to increase to 100 units. "This may be the only country currently open and moving forward in this COVID era, and precisely where our CEO is located."

Rapid redesign and turnaround are key. Mondesir stated, "If we can move at this speed, we can make changes at any time; if something doesn't work, we can change it and continue. Automation makes all of this possible."