Feasibility analysis of robot-assisted processes for automated tolerance compensation by using additive manufacturing

By using direct joining presses in combination with thermal material extrusion processes, individually adapted spacers made of polyethylene terephthalate which is prepared with glycol can be applied to conventionally manufactured components made of acrylonitrile-butadiene-styrene copolymer in order to automatically compensate bigger deviations. In this study, a prototype system, especially built for this application was developed to analyze a flexible compensation method for deviated parts, made by injection moulding. By using a KUKA robot, the freedoms of movement are increased compared to a cartesian system. The main objective by using this method is, to investigate the dimensional accuracy of the applied samples and the required production time. Selected process modifications are used to further optimize the dimensional accuracy and production time. The evaluation and assessment of the applied samples is performed by using a line scanner. The results suggest that manufacturing processes can be made more accurate and cost effective.