Standardised additive manufacturing series for integrated 3D printing
A collaboration between additive manufacturing software specialist Ai Build and KUKA Systems UK has culminated in the development of the AMCell_ series of turnkey, integrated 3D printing systems.
The series born out of the collaboration between Ai Build and KUKA Systems launched with the AMCell_small, the first of three standardised cell iterations. AMCell_small is aimed specifically at the academic sector, for schools, universities and company training facilities, through which students can learn the basics of automated polymer, 3D printing.
Featuring the KUKA KR AGILUS 10 R900, Ai Build’s additive manufacturing software AiSync, a non-planar extruder head and periphery, AMCell_ has been efficiently and cost-effectively packaged to support the optimal delivery of advanced training methods in additive manufacturing principles.
The competent handling of automated, technological products is of paramount importance in today’s manufacturing environment. The assembly of products is undergoing a revolution, and additive manufacturing is a key driver behind this trend, as it becomes the mass-manufacturing method of choice as digitally automated workflows replace high-volume, serial production techniques.
The AGILUS KR10 robot, shown here in another application, is integrated with Ai Build’s AiSync software in the new AMCell_ series.
3D printing is now considered a standard part of manufacturers’ toolkits across industry sectors, such as automotive, aerospace, marine and energy/power generation, as a cost-effective and accelerated alternative to conventional techniques, such as near-net-shape and subtractive manufacturing. Tooling, door handles, dashboards, and keels are all being produced using 3D printing methods, as manufacturers satisfy both aesthetic and functional considerations.
As demand for additive manufacturing as a process has increased, Ai Build has focussed on developing its AiSync software that enables the fast, precise and repeatable delivery of highly efficient toolpaths using KUKA’s industrial robots. A programme of continuous solution development that encapsulated machine learning and artificial intelligence means that today, AiSync customers can achieve overall build efficiency gains of a staggering 90% and build failure reductions of 65%.
The AMCell_ series, primarily the next cell generations of _medium and _large, shall deliver a fully autonomous ‘go-to’ solution that will satisfy demand-driven additive manufacturing requirements in sectors such as automotive and aerospace.
” Our approach is to enable broad adoption of 3D printing, the key to which is ease of use and repeatable outcomes,” said AiBuild CEO Daghan Cam. “Our collaboration with KUKA on the AMCell aligns perfectly with that aim within a fully integrated, high quality system”.
Ai Build has partnered with KUKA UK for seven years, from the beginning of the Ai journey. The brand has been an integral member of the hugely successful system partner programme ever since, sharing best practices and transference of knowledge. Therefore, it made sense that the mutual strengths of both brands be utilised in developing the AMCell_ series.
“A small-scale, polymer 3D printing package aimed (initially) at the academic sector seemed the perfect fit for KUKA and Ai Build,” said Kevin Kolkea, Sales Manager – Robotic Joining and Additive Manufacturing at KUKA. “As an entry-level standardised cell, our skilled 3D printing specialists of tomorrow can be trained in the operation of KUKA robots and become familiar with Ai Build’s additive manufacturing software, AiSync, and user interfaces.”
The AMCell_small will take the delivery of 3D printing in academia to another level which, typically, has been utilising computer-aided design (CAD) information to print products via a 3D printer. Technology packages such as the AMCell_ allow for much larger scale projects to be delivered, synergies between creativity and technology to be realised, prototypes can be accelerated, and adaptable and scalable processes can be developed for industry.
The fully integrated AMCell_ package will give students the capability to start manufacturing their own products and prototypes whilst institutions save costs on tooling, maintenance and development. AMCell_ maximises the degrees of freedom in the additive manufacturing, plastic extrusion process, using a preconfigured robot and AiSync software to suit individual requirements with small print areas.
Kevin continued: “Manufacturers now want the efficiencies that 3D printing affords, that correlate to cost savings, accelerated market entry and enhanced product integrity. More importantly, they want access to skilled individuals who can manage their process chains within automated additive manufacturing, especially in the current labour climate.”
Daghan further commented: “KUKA has a well-earned reputation for quality engineering, and over many years Ai Build’s partnership with KUKA has been tested in many scenarios. We use KUKA robots daily in our Ai lab, and KUKA integrated with AiSync software has been successfully pushing AM boundaries in the world’s largest enterprises. We are delighted to have had the opportunity to collaborate with KUKA on the AMCell, which addresses a clear market need across academia and enterprise alike.
