KUKA aids vital research into additive manufacturing
A BLACK Country robotics firm has helped to deliver an important new research project in the field of bulk additive manufacturing.
Automation specialist KUKA Systems UK worked with research engineers from the Nuclear Advanced Manufacturing Research Centre at Sheffield University to design a 10m x 5m production cell for building near net shape parts from the ground up as well as adding metal features to large structures.
The cell comprises a six-axis KUKA robot, mounted on a three-axis, 5m high gantry, and a two-axis manipulator with 3.5m diameter turntable. The robot arm is equipped with an arc welding system that integrates the wire feed into a welding torch.
The robot works directly from a CAD model to lay down weld material to create three dimensional parts and add non-critical features to structures such as large pump and valve casings or pressure vessels.
In addition, the robot enabled the research team to not only deploy a range of welding techniques using metal powder and wire, but also inspect and finish parts in a single set-up.
The project, funded by the High Value Manufacturing Catapult, is designed to show how additive manufacturing can be more easily introduced into existing production lines.
Halesowen-based KUKA had previously worked on developing a small, shaped metal deposition cell that was originally supplied to Rolls-Royce and later moved to the Nuclear AMRC facility.
Dave Burns, KSUK’s project sales engineer, said: “The research team asked KUKA to tender for a bigger cell based on the same technology so that they could work on larger components. A new design was evolved and the new cell was built and installed over a six-month period.”
Discussions are now underway with the Nuclear AMRC team on how to upgrade the cell and further expand its capabilities and flexibility.
KUKA Systems UK produces automated production solutions for a wide range of industry sectors including aerospace, automotive and nuclear decommissioning.
