Blue Danube Robotics Used Carbon 3D Printing Tech To Rapidly Manufacture Custom Industrial Parts: Here's How

Learning Centre > Blue Danube Robotics Used Carbon 3D Printing Tech To Rapidly Manufacture Custom Industrial Parts: Here's How

Blue Danube Robotics is always looking for ways to make industrial robots safer so that they can work with people.

Blue Danube Robotics is always looking for ways to make industrial robots safer so that they can work with people. Blue Danube Robotics is always looking for ways to make industrial robots safer so that they can work with people.
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Blue Danube Robotics is always looking for ways to make industrial robots safer so that they can work with people. This company wants to create mass production with safe human-robot collaboration. Humans and robots may collaborate on activities while maintaining safety with fenceless apps. Robots can automatically switch off when danger is discovered using sensors, allowing for faster processing and reduced downtime.

The firm is based in Vienna, Austria, and specializes in developing add-on safety sensor systems for robots to make medium-sized and huge businesses more efficient and productive while also prioritizing safety precautions.

Blue Danube Robotics' AIRSKIN technology is a strong, pressure-sensitive skin that is directly installed onto common industrial robots. The flexibility of AirSkin makes it ideal for robots with a wide range of sizes, shapes, and functions. The solution not only includes a skin, but also palletizing, visual inspection, and machine maintenance applications that aid different customers in finding the best fit for their robots. AIRSKIN strives to make workplaces more efficient everywhere through the use of its solutions.

CHALLENGE: Creating easy to clean, customised parts

AIRSKIN's early prototypes were created using a variety of techniques and materials, including molded open-cell foam coated with polyurethane and roto-casted shells which were subsequently filled with open-cell foams.

Blue Danube Robotics has spent years studying the 3D printing sector and tried out nearly 20 different printer manufacturers and part suppliers to develop the various components of the AIRSKIN model. Given that each client's AIRSKIN model is unique, Blue Danube Robotics wanted a manufacturing technique that would enable low-volume custom production of each component.

Before attempting Carbon Digital Light Synthesis (Carbon DLS), Daniel Green Danube Robotics collaborated with Selective Laser Sintering (SLS) to fabricate AIRSKIN models utilizing the Carbon DLS technique.

Carbon DLS technology proved ideal for designing and producing smaller pad sensors and other additional components used in the AIRSKIN model, such as mounting brackets, magnet holders, and cable clips. According to Blue Danube Robotics, SLS components are too inflexible to form small parts. Cleaning SLS components during the dust removal process is frequently difficult or impossible.

SOLUTION: Achieving a high level of accuracy and consistency

The manufacturing procedure for an AIRSKIN model entails the formation of numerous part groups, including the enormous pads on the outside, the support structure (support layer) on the robot, the cabling, and installation.

KUKA-ROBOT-SUPPORT-AIRSKIN.png

The AIRSKIN model's various mounting brackets that help to support the placement of the pads on the robot area are an important element. All of these components must be developed simultaneously in order for a good fit for mobile robots to be obtained. New parts are often required due to the need for customisation, even though Blue Danube Robotics attempts to utilize.

Carbon DLS was used to manufacture the complicated components of parts with Blue Danube Robotics. Small sensors for AIRSKIN, for example, need a wall thickness of 0.8–0.9mm in order to sense forces around 0.5 newtons (50g), which was previously unattainable using conventional 3D manufacturing approaches.

To allow the various AIRSKIN component parts to connect, a perfect fit is required. To preserve the integrity and functionality of the piece, Blue Danube Robotics must be able to easily clean components. Even after using SLS to clean components, dust residue remained on them, affecting part fit. Carbon DLS technology produces parts with a superior surface finish.

Carbon software also allowed Blue Danube Robotics to make quick and easy modifications to custom parts throughout the design and manufacturing process. Instead of having to build everything from scratch after each testing round, Blue Danube could make changes right on the most recent design of components.

Specialized custom AIRSKIN pads made from Carbon EPU 41

Blue Danube Robotics may have used a variety of materials when developing the various component components in AIRSKIN, had it not been for the wide range of 3D printing materials available in the Carbon material family. Blue Danube Robotics opted to employ Carbon EPU 41, EPU 40, and UMA 90 after thorough testing between Carbon materials and others.

Blue Danube Robotics required high resiliency and a material with the flexibility to withstand an industrial environment for its AIRSKIN pads, so Carbon EPU 41, a highly elastic, tear-resistant, and energy-returning elastomeric polymer that meets all of Blue Danube Robotics' requirements, was ideal.

For industrial robots that need to connect the controller with the tool connected to the machine, Blue Danube Robotics required a flexible and robust material for supporting zip tie holes in the design. Carbon EPU 40 was chosen for its material characteristics, including EPU 41's, and because it is black.

For its design, Carbon UMA 90 was chosen by Blue Danube Robotics since it can print many components simultaneously and quickly. The features of UMA 90 allowed Blue Danube Robotics to rapidly iterate through component concepts to improve for simple cleaning and post-processing.

AIRSKIN mounting brackets for big industrial robots made from Carbon UMA 90

Streamlining customisable low-volume production

Managing the customisation for each order is one of AIRSKIN's most difficult tasks, which is why finding a technology that supports flexible and scalable low-volume custom production was so important for Blue Danube Robotics. The Carbon DLS method and Carbon M2 3D printer helped to speed up the development process by allowing small runs of bespoke parts

AIRSKIN cable mountings for industrial robots made from Carbon EPU 40

With other technologies, it might take Blue Danube Robotics a week to design and fabricate a unique part. Using the Carbon DLS method allowed Blue Danube Robotics to deliver components in one day, improving client satisfaction while also enhancing robot compatibility with Blue Danube Robotics' AIRSKIN system.

“Working with Carbon DLS technology and the high-quality materials available through Carbon allowed us to optimise the production of our AIRSKIN technology and helped us to achieve the requirements for specific pieces. Carbon is helping to enable the future of fenceless collaborative applications through the ability to create better designs in less time.” - Andreas Baldinger, CEO, AIRSKIN

Blue Danube Robotics can now provide rapid prototyping in-house and quickly produce custom parts for industrial goods to help accelerate a wide range of fenceless applications for robotics. After the successful collaboration in creating the AIRSKIN model, Blue Danube Robotics continues to create components with a perfect fit and seeks for means to incorporate Carbon technology into new applications.

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Blue Danube Robotics is always looking for ways to make industrial robots safer so that they can work with people. This company wants to create mass production with safe human-robot collaboration. Humans and robots may collaborate on activities while maintaining safety with fenceless apps. Robots can automatically switch off when danger is discovered using sensors, allowing for faster processing and reduced downtime.

The firm is based in Vienna, Austria, and specializes in developing add-on safety sensor systems for robots to make medium-sized and huge businesses more efficient and productive while also prioritizing safety precautions.

Blue Danube Robotics' AIRSKIN technology is a strong, pressure-sensitive skin that is directly installed onto common industrial robots. The flexibility of AirSkin makes it ideal for robots with a wide range of sizes, shapes, and functions. The solution not only includes a skin, but also palletizing, visual inspection, and machine maintenance applications that aid different customers in finding the best fit for their robots. AIRSKIN strives to make workplaces more efficient everywhere through the use of its solutions.

CHALLENGE: Creating easy to clean, customised parts

AIRSKIN's early prototypes were created using a variety of techniques and materials, including molded open-cell foam coated with polyurethane and roto-casted shells which were subsequently filled with open-cell foams.

Blue Danube Robotics has spent years studying the 3D printing sector and tried out nearly 20 different printer manufacturers and part suppliers to develop the various components of the AIRSKIN model. Given that each client's AIRSKIN model is unique, Blue Danube Robotics wanted a manufacturing technique that would enable low-volume custom production of each component.

Before attempting Carbon Digital Light Synthesis (Carbon DLS), Daniel Green Danube Robotics collaborated with Selective Laser Sintering (SLS) to fabricate AIRSKIN models utilizing the Carbon DLS technique.

Carbon DLS technology proved ideal for designing and producing smaller pad sensors and other additional components used in the AIRSKIN model, such as mounting brackets, magnet holders, and cable clips. According to Blue Danube Robotics, SLS components are too inflexible to form small parts. Cleaning SLS components during the dust removal process is frequently difficult or impossible.

SOLUTION: Achieving a high level of accuracy and consistency

The manufacturing procedure for an AIRSKIN model entails the formation of numerous part groups, including the enormous pads on the outside, the support structure (support layer) on the robot, the cabling, and installation.

KUKA-ROBOT-SUPPORT-AIRSKIN.png

The AIRSKIN model's various mounting brackets that help to support the placement of the pads on the robot area are an important element. All of these components must be developed simultaneously in order for a good fit for mobile robots to be obtained. New parts are often required due to the need for customisation, even though Blue Danube Robotics attempts to utilize.

Carbon DLS was used to manufacture the complicated components of parts with Blue Danube Robotics. Small sensors for AIRSKIN, for example, need a wall thickness of 0.8–0.9mm in order to sense forces around 0.5 newtons (50g), which was previously unattainable using conventional 3D manufacturing approaches.

To allow the various AIRSKIN component parts to connect, a perfect fit is required. To preserve the integrity and functionality of the piece, Blue Danube Robotics must be able to easily clean components. Even after using SLS to clean components, dust residue remained on them, affecting part fit. Carbon DLS technology produces parts with a superior surface finish.

Carbon software also allowed Blue Danube Robotics to make quick and easy modifications to custom parts throughout the design and manufacturing process. Instead of having to build everything from scratch after each testing round, Blue Danube could make changes right on the most recent design of components.

Specialized custom AIRSKIN pads made from Carbon EPU 41

Blue Danube Robotics may have used a variety of materials when developing the various component components in AIRSKIN, had it not been for the wide range of 3D printing materials available in the Carbon material family. Blue Danube Robotics opted to employ Carbon EPU 41, EPU 40, and UMA 90 after thorough testing between Carbon materials and others.

Blue Danube Robotics required high resiliency and a material with the flexibility to withstand an industrial environment for its AIRSKIN pads, so Carbon EPU 41, a highly elastic, tear-resistant, and energy-returning elastomeric polymer that meets all of Blue Danube Robotics' requirements, was ideal.

For industrial robots that need to connect the controller with the tool connected to the machine, Blue Danube Robotics required a flexible and robust material for supporting zip tie holes in the design. Carbon EPU 40 was chosen for its material characteristics, including EPU 41's, and because it is black.

For its design, Carbon UMA 90 was chosen by Blue Danube Robotics since it can print many components simultaneously and quickly. The features of UMA 90 allowed Blue Danube Robotics to rapidly iterate through component concepts to improve for simple cleaning and post-processing.

AIRSKIN mounting brackets for big industrial robots made from Carbon UMA 90

Streamlining customisable low-volume production

Managing the customisation for each order is one of AIRSKIN's most difficult tasks, which is why finding a technology that supports flexible and scalable low-volume custom production was so important for Blue Danube Robotics. The Carbon DLS method and Carbon M2 3D printer helped to speed up the development process by allowing small runs of bespoke parts

AIRSKIN cable mountings for industrial robots made from Carbon EPU 40

With other technologies, it might take Blue Danube Robotics a week to design and fabricate a unique part. Using the Carbon DLS method allowed Blue Danube Robotics to deliver components in one day, improving client satisfaction while also enhancing robot compatibility with Blue Danube Robotics' AIRSKIN system.

“Working with Carbon DLS technology and the high-quality materials available through Carbon allowed us to optimise the production of our AIRSKIN technology and helped us to achieve the requirements for specific pieces. Carbon is helping to enable the future of fenceless collaborative applications through the ability to create better designs in less time.” - Andreas Baldinger, CEO, AIRSKIN

Blue Danube Robotics can now provide rapid prototyping in-house and quickly produce custom parts for industrial goods to help accelerate a wide range of fenceless applications for robotics. After the successful collaboration in creating the AIRSKIN model, Blue Danube Robotics continues to create components with a perfect fit and seeks for means to incorporate Carbon technology into new applications.

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