Over the past decades, robotic automation has expanded in numerous industrial sectors; however, manufacturing operations involving the manipulation of non-rigid products are mostly preserved manual. The dynamic distortion of flexible objects underlines limitations in robot cognition and dexterity. Inspired by the gaps in composites industry automation, this paper presents a novel multifunctional robot end-effector for the robotic automation of composites layup. Aiming a holistic confrontation of layup challenges, the proposed end-effector incorporates tools for (a) the manipulation of sheet materials, like composite fabrics of variable dimensions; (b) the grasping of core materials, like foam blocks; (c) the handling of peripheral tools; (d) the exertion of fitting forces; and (e) the application of resin in diverse mold geometry cavities. The meticulous design of the end-effector’s configuration allows for consistent and collision-free tool usage with no excess robot tool changes, granting even higher productivity and efficiency. The enhancement in robot dexterity and proficiency for layup operations is validated within an automotive case, where semi-automation is intended for the improvement in overall workstation’s efficiency, quality, ergonomics, and well-being.
