3D Printing: A New Manufacturing Method Revolutionizing the Robotics Industry

The Growing Adoption of 3D Printing in Robotics

In recent years, the use of 3D printing (additive manufacturing) in robotics has grown rapidly among companies and research institutions. Components such as frames, joints, and housings, which traditionally relied on molding or CNC machining, are now being produced with 3D printers, changing the manufacturing paradigm of the robotics industry.

With 3D printing, robotics development benefits from lightweight design, customization, and complex geometries, making it increasingly impactful not only for research and prototyping but also for small-scale commercialization.

Why Is 3D Printing Needed in Robot Manufacturing?

The process of building robots requires four essential conditions to be met simultaneously: fast development cycles, customization, lightweight design, and complex structures. Traditional manufacturing methods often fail to achieve all of these, whereas 3D printing effectively addresses them.

Faster development cycles: Modify design → print → test → redesign, all within a matter of days.
Customization: Cost-effective even for small volumes, enabling parts tailored to specific applications.
Lightweight design: Lattice structures and topology optimization allow parts that are lighter yet stronger than conventionally machined ones.
Functional integration: Cable guides, cooling channels, and sensor mounts can be integrated into a single print, reducing parts count and assembly time.

Thus, 3D printing has become a core technology that complements traditional processes while solving the key challenges of speed, cost, quality, and design freedom.

Why 3D Printing Is Well-Suited for Robotics

The robotics industry often faces frequent design changes and requires extensive prototyping. 3D printing provides unique advantages in such environments:

Research & educational robots: Fast development cycles and cost efficiency allow diverse models to be created quickly.
Service & logistics robots: Enables customized designs for sensors, batteries, and other application-specific features.
Wearable & medical robots: Allows for user-specific customization tailored to body shape and medical needs.

In short, 3D printing provides a practical solution that meets the diverse demands of robotics across research, logistics, and medical fields, while opening new pathways for innovation.

Key Considerations in 3D Printed Robotics

While 3D printing offers many advantages, manufacturers must also consider potential challenges to ensure stable production.

Material properties: Choosing the right material—PA12, carbon-fiber composites, TPU—depending on application.
DfAM (Design for Additive Manufacturing): Designing specifically for 3D printing instead of merely converting CNC designs.
Post-processing and quality control: Surface finishing and dimensional adjustments are critical for precision parts.
Cost/scale analysis: Large-scale mass production is still more efficient with traditional manufacturing.

By considering materials, design methods, post-processing, and production scale, manufacturers can maximize the efficiency and quality of 3D printed robot production.

Case Studies in 3D Printed Robotics

3D printing has moved beyond prototyping to enable the production of robotic hands, humanoid robots, and quadruped robots. This demonstrates its ability to meet demands for lightweight design, customization, and cost reduction.

ASS Maschinenbau (Germany): Produced industrial robot grippers and robotic hand parts with EOS 3D printers using PA12 polyamide, achieving both lighter components and reduced costs. (EOS Case Study)
Ghost Robotics (USA): Developed the quadruped robot Spirit using 3D printed parts, cutting production costs to one-quarter of the original. (Trimech Advanced Manufacturing)
Berkeley Humanoid Lite (UC Berkeley, USA): An open-source humanoid robot with most of its structure 3D printed, produced for less than $5,000—making it highly accessible for education and research. (Berkeley Engineering)

These examples show that 3D printing is no longer limited to prototyping but is proving its competitiveness in real-world commercialization.

Driving Robotics Innovation with 3D Printing — Together with Creallo

3D printing brings true innovation to robot manufacturing by simultaneously delivering design freedom, faster development, and customized solutions. It is especially effective for research, education, prototypes, and small-batch production.

At Creallo, we support numerous robotics companies as a trusted manufacturing partner, not only for prototypes but also for scaling up to production. With our in-house facilities and global manufacturing network, we provide industrial-grade 3D printing, precision CNC machining, vacuum casting, and more. Our promise: high quality, fast delivery, and tailored solutions that meet the unique needs of robotics innovators.

As robotics advances toward lighter, faster, and more customized designs, 3D printing will become an essential choice. Start your next robotics project with Creallo and stay ahead of the curve.

Find out more about Creallo 3D Printing Service →

Visit Creallo at RobotWorld 2025: Booth B29. Explore 3D-printed robotic parts and experience the quality of our multi-process manufacturing firsthand.