Design of a Robot Vacuum Gripper Manufactured with Additive Manufacturing Using DfAM Method

This study presents a Design for Additive Manufacturing (DfAM)–driven redesign of an industrial robot vacuum gripper for Fused Deposition Modeling (FDM), focusing on the systematic transformation of a multi-part, machined aluminum assembly into a lightweight, support-minimized polymer component suitable for continuous industrial operation. Beyond a practical redesign, the work contributes a geometry-centered DfAM methodology that links internal channel topology, overhang control, and functional interfaces to manufacturability, vacuum performance, and cost efficiency. The development follows three iterative design revisions, progressing from a geometry-adapted baseline toward a fully DfAM-optimized solution. A key innovation is the introduction of support-free internal vacuum channels with triangular cross-sections, enabling complete elimination of soluble support material within enclosed cavities. This redesign reduces the internal vacuum volume by 44%, leading to faster vacuum response while maintaining functional suction performance. The optimized overhang angles, filleted load paths, and DfAM-compliant suction cup seats significantly reduce post-processing requirements and improve structural robustness. Experimental validation under industrial operating conditions confirms that the final design achieves reliable vacuum performance and mechanical durability. Compared to the original configuration, the optimized gripper demonstrates a substantial reduction in manufacturing complexity, with printing time reduced by approximately 50% and total part cost decreased by 26%, primarily due to eliminated tooling, reduced support material, and simplified post-processing. The presented results demonstrate that DfAM principles, when applied systematically at both global and internal geometry levels, can yield quantifiable functional and economic benefits. The findings provide transferable design guidelines for support-free internal channels and functional interfaces in FDM-manufactured vacuum components, offering practical reference points for researchers and practitioners developing end-use additive manufacturing solutions in industrial automation.