01 / Challenge
Challenge
The client had a working kinematic simulation and no hardware. They needed a physical arm within two weeks to validate reach envelope and joint clearance before committing to machined aluminium.
Engineering Prototype — 2025
Custom Robot Arm
A five-axis desktop manipulator printed as fourteen interlocking parts, designed so every joint could be serviced without cutting anything apart.
PETGFDMEngineering
Preparing 3D view
Loading geometry and materials.
- Project
- Custom Robot Arm
- Material
- PETG
- Technology
- FDM
- Print Time
- 18 hours
- Layer Height
- 0.20 mm
- Weight
- 640 g
- Dimensions
- 180 x 180 x 420 mm
- Industry
- Engineering
02 / Design
Design
We re-cut the CAD into fourteen printable sections split along stress-neutral planes, added captive nut pockets for M4 hardware and thickened the shoulder joint where the simulation showed peak bending load.
03 / Printing Process
Printing Process
Printed in PETG at 0.2 mm with four perimeters and 40 percent gyroid infill. Joints were printed at 0.12 mm for a tighter running fit. Total unattended machine time was 18 hours across two printers.
04 / Final Result
Final Result
The arm assembled without rework and held its reach envelope within 1.5 mm of simulation. Two clearance problems were found and corrected in CAD before any metal was cut.
Gallery
Through the build
Four moments from the job, in the order they happened.
- 01
Shoulder joint, printed in two halves - 02
Elbow assembly with captive hardware - 03
Full arm, assembled and cabled - 04
Base plate and rotation bearing
More Work
Related projects
- Engineering2025
- 26 hrs
- Layer
- 0.12 mm
- Weight
- 410 g
Planetary Gearbox
A 27:1 reduction stage printed in carbon-filled nylon, running continuously on a test rig for over two hundred hours without measurable backlash growth.
- CARBON FIBER
- FDM
- Functional Drive Component
- Engineering2025
- 11 hrs
- Layer
- 0.12 mm
- Weight
- 165 g
Impeller Flow Study
Six impeller geometries printed in a single overnight run so a pump manufacturer could test blade profiles against real water.
- PETG
- FDM
- Fluid Dynamics Validation
- Architecture2026
- 34 hrs
- Layer
- 0.05 mm
- Weight
- 1850 g
Riverside Tower Model
A 1:200 presentation model of a mixed-use tower, printed in nine sections with a translucent resin curtain wall lit from within the base.
- RESIN
- SLA
- Competition Presentation Model
Custom Robot Arm
Create something similar.
Send us your model, or describe the object and we will build the model too.
Or call +91 93444 98634