Innovative automation: How BÖLLHOFF uses the LPBF process to increase the efficiency of robot handling systems

In 2019, BÖLLHOFF revolutionized internal automation solutions in injection molding processes with the introduction of additive manufacturing. The innovative 3D printing technology addresses key challenges and fulfills wishes, such as reducing the still very high weight of robot handling systems, the production of complex geometries and the long production cycles of conventional gripper and handling systems. The redesign (3D print-compatible design) of existing systems and the use of aluminium in selective laser melting in collaboration with DMG MORI resulted in a lightweight, durable system with integrated air ducts that not only reduces the weight of the components, but also minimizes the assembly effort and the number of leakage points. Several functions can also be easily integrated into this system with virtually no additional effort. The classic “complexity for free” approach has been implemented. This creates real added value at BÖLLHOFF.

Furthermore, the single-step production of 3D printing significantly increases the availability of functional and spare parts and enables rapid adjustments to be made in the event of frequently changing requirements, which also significantly shortens the time to market for the product. An outstanding example is an additively manufactured gripper system for a 24-cavity injection mold, which not only achieves cost parity with traditional methods, but also offers superior functionality. The lecture will present further internal and external application examples, such as an additively manufactured gripper system for removing bipolar plates from a press tool from Whitecell Eisenhuth, which impressively demonstrate the benefits of 3D printing in the field of handling systems.

A further and complementary innovative feature of this new technology at BÖLLHOFF is the marking of the components using additively manufactured QR codes in cooperation with the company Additive Marking. The digital fingerprint enables complete traceability during the entire product development process, the production process and later also in the procurement of spare parts.

The further development of the DMG MORI SLM machine as a productive and efficient solution for the production of high-quality additive finished parts leads to new and further customer-specific solutions both internally at BÖLLHOFF and for its external customers. The benefits are enormous, both in monetary terms and in the perception of the company's ability to innovate.

Presentation language: GER