ForgeLabs Advanced ManufacturingForge Labs

Robotics 3D Printing for Grippers, End Effectors and Robot Components

Production parts and tooling for robotics developers in nylon, elastomer, clear resin and metal, made in North America from the first trial kit to repeat lots.

  • Repeat production lots with heat-set inserts installed and first article inspection on request.
  • Carbon-fibre nylon end effectors up to 60% lighter than aluminium.
  • From 2 business days, with next day shipping anywhere in the US and Canada.
Get an instant quoteTalk to an engineer
Robotics 3D Printing Solutions
Robotics Overview

From trial kit to production robot parts

Robotics teams use Forge Labs for parts that change with every build and rarely justify a mould: finger links and grip pads for humanoid hands, clear gearbox and actuator housings, gripper fingers with printed flexures, sensor enclosures with threaded inserts installed, electronics chassis for subsea pressure housings, handed bump stops for wearable robots, and the jigs and fixtures used to assemble them. We make them in North America with SLS, MJF, FDM, SLA, PolyJet and DMLS, from 2 business days with 24-hour turnaround on request, and ship next day anywhere in the US and Canada.

Where additive creates leverage

Parts that arrive ready for assembly

Forge Labs helps teams move from design validation to production-ready parts without waiting on tooling lead times. Consolidated assemblies, lighter parts, and faster revisions give engineering teams more control over schedule, cost, and performance.

Key manufacturing benefits

  • Move from a trial kit to production lots without paying for tooling.
  • Revise a design between lots and print the new file in the next one.
  • Order mirrored left- and right-hand parts as matched sets.
  • Receive parts with heat-set inserts installed and part IDs printed in.
  • Source nylon, elastomer, clear resin and metal parts from one supplier.
  • Iterate quickly, with lead times from 2 business days and next day shipping anywhere in the US and Canada.
Get an instant quoteTalk to an engineer
Robotics Manufacturing Process 1
Robotics Manufacturing Process 2
Robotics Manufacturing Process 3
Robotics Manufacturing Process 4
Quality and compliance

Production workflows for robotics hardware

Robotics customers send drawings with GD&T and general tolerance blocks, ask for first article inspection when a drawing or order calls for it, and reorder unchanged files for months. We support that with dimensional inspection, first article inspection or production sampling where offered, and supplier material data, from the first lot to the latest reorder.

Supplier material data
Strength, temperature, flame and static-dissipative data from material suppliers, with fatigue data where the supplier publishes it, for your robot cell risk assessment and test plans.
Revisions between lots
A revised file goes into the next lot with no tooling change.
First article and production sampling
Add first article inspection or production sampling to an order where offered for the material, before and during repeat production.
ISO 9001-aligned inspection
Parts are inspected under processes aligned with ISO 9001. Dimensional inspection reports and material certifications are provided on request.
Inserts, dyeing and part marking
Heat-set inserts installed, parts dyed black or a custom colour, and part IDs printed into the surface before shipping.
Ordering and repeat lots
Attach drawings with tolerance callouts, track order status from upload to delivery, and reorder lots from your order history.
Get an instant quoteTalk to an engineer
Manufacturing Capabilities

3D Printed Robotics Parts and Robot Cell Tooling

The robot parts our customers order most, grouped by application, with the processes, materials and material data behind each.

SLS nylon gripper fingers with printed-in flexures on a pick-and-place arm
SLS nylon gripper fingers with printed-in flexures on a pick-and-place arm

End-of-arm tooling

Custom End Effectors & Grippers

SLS PA12 makes gripper fingers, arm links and end-of-arm mounts with printed flexures; critical pivot bores can be machined to H7 fits after printing. FDM PAHT-CF carbon-fibre nylon makes stiff, light tooling. A warehouse-automation gripper combined pneumatic channels, force sensors and adaptive grip geometry in a printed design that weighed 50% less than its machined version. Prototype iterations were 75% faster, assembly was simpler and the gripper handled a wider range of items. Carbon-fibre nylon end effectors can be up to 60% lighter than aluminium.

Typical parts
Gripper fingers, arm links, end-of-arm mounts
Key properties
Printed flexures; pivot bores machined to H7; SLS ±0.3% (min ±0.3 mm)
Material data
PAHT-CF: 3,860 MPa tensile modulus (X-Y), 170 °C HDT at 1.8 MPa
Materials
Nylon PA12 (SLS)PAHT-CF Carbon Fiber Nylon (FDM)
SLS nylon finger links with PolyJet elastomer grip pads on a five-finger robotic hand
SLS nylon finger links with PolyJet elastomer grip pads on a five-finger robotic hand

Multi-finger hands and wrists

Humanoid Hands, Grip Pads & Covers

SLS PA12 suits finger segments and palm plates for multi-finger robot hands. Separate PolyJet grip pads on SLA backing plates let teams change texture and hardness without redesigning the nylon structure. Agilus30 blends span Shore A 30 to 95; PolyJet can also co-print rigid VeroClear and flexible Agilus30 in one part. Shells, frames and wrist housings can be made in left- and right-hand versions, with natural or dyed nylon finishes.

Typical parts
Finger links, palm plates, grip pads, backing plates, back-of-hand shells, wrist housings
Key properties
Left/right versions; natural, dyed black or custom colour; SLS ±0.3% (min ±0.3 mm)
Material data
Agilus30: Shore A 30–95 by blend; Nylon PA12: 20% elongation at break (X/Y)
Materials
Nylon PA12 (SLS)Agilus30 (PolyJet)VeroClear (PolyJet)Accura 25 (SLA)
Clear SLA gearbox housing with Accura 25 planet gears on a test bench
Clear SLA gearbox housing with Accura 25 planet gears on a test bench

Joints and drive trains

Actuators, Gearboxes & Drive Parts

Accura ClearVue housings, carriers and output shafts let engineers watch a planetary stage turn, with most gears printed in Accura 25. SLS PA12 makes timing pulleys, sprockets and gears with tooth profiles and keyed or square bores printed in. A small set of gears with graduated size offsets lets engineers compare fit before freezing the file. Clear actuator housing sets can be printed across a range of frame sizes without tooling.

Typical parts
Actuator housings, planetary gears and carriers, timing pulleys, sprockets
Key properties
Printed tooth profiles and keyed bores; fit trials without tooling; SLA ±0.25% (min ±0.25 mm)
Material data
Accura ClearVue: 87.2% luminous transmittance; Nylon PA12: 50 MPa tensile
Materials
Accura ClearVue (SLA)Accura 25 (SLA)Nylon PA12 (SLS)
Handed SLS nylon bump stops in matched left- and right-hand pairs
Handed SLS nylon bump stops in matched left- and right-hand pairs

Powered joint actuators

Exoskeleton & Wearable Robotics

SLS makes small actuator parts in repeat lots: PA12 travel stops in matched left- and right-hand versions, clamp plates and flexible TPU wire clips. Resin printing makes toothed pulleys, while stiffer Glass Filled Nylon PA12 suits mount plates. Accura 25 split moulds support overmoulding without machining a metal tool. Small parts can share builds, and a revised housing file goes into the next lot without retooling.

Typical parts
Bump stops, toothed pulleys, clamp bars, wire clips, actuator housings
Key properties
Handed left/right pairs; SLS ±0.3% (min ±0.3 mm)
Material data
Glass Filled Nylon PA12: 3,200 MPa tensile modulus (XY); Nylon PA12: 0.93 g/cm³
Materials
Nylon PA12 (SLS)Glass Filled Nylon PA12 (SLS)Accura 25 (SLA)
SLS nylon sensor enclosure and lid with threaded inserts installed, beside an internal tray
SLS nylon sensor enclosure and lid with threaded inserts installed, beside an internal tray

Vision and sensing

Sensor & Camera Mounting Systems

SLS PA12 makes sensor enclosures, lids and mounts as matched kits. Holes, ports and mounting slots print into a one-piece enclosure; heat-set inserts are specified by thread, installed length, material and count. MJF PA12 makes light shields, SLS makes gasket frames, and PolyJet makes VeroClear covers and thin Agilus30 gaskets. Accura ClearVue makes diffusers and light pipes for status lighting. Keep the insert specification and file revision consistent across every kit and reorder.

Typical parts
Sensor enclosures, lids, trays, mounts, light shields, gasket frames, light pipes
Key properties
Heat-set inserts installed; SLS ±0.3% (min ±0.3 mm)
Material data
HP PA12: 50 MPa tensile (XY and Z); VeroClear: simulates clear acrylic (PMMA)
Materials
Nylon PA12 (SLS)HP High Reusability PA12 (MJF)VeroClear (PolyJet)Agilus30 (PolyJet)Accura ClearVue (SLA)
Black SLS nylon electronics chassis sliding into a subsea pressure housing
Black SLS nylon electronics chassis sliding into a subsea pressure housing

Pressure housings and vehicle exteriors

Subsea & Field Robot Hardware

SLS PA12 electronics chassis hold circuit cards inside pressure housings. Card brackets, support rails and cable posts print as mixed kits; slotted holes let curved slide pads adjust to the housing bore during assembly. Part IDs can be printed into the surface, and unchanged files support repeat lots. Larger inlet and sensor-guard rings use the same process, with part size and orientation reviewed against the 340 × 340 × 600 mm SLS build envelope.

Typical parts
Electronics chassis, slide pads, inlet rings, sensor guards
Key properties
Slotted assembly fits; printed part IDs; 340 × 340 × 600 mm SLS envelope
Material data
Nylon PA12: 92 kV/mm dielectric strength, 0.93 g/cm³
Materials
Nylon PA12 (SLS)
FDM ASA cover fitted to a robot-cell equipment cabinet
FDM ASA cover fitted to a robot-cell equipment cabinet

Welding automation and robot cells

Welding & Robot Cell Hardware

FDM ASA makes equipment covers, Nylon 12 makes mechanical stops and carbon-fibre nylon makes flexure springs for robot cells. Released drawings can specify the material, layer height, fill and build direction, with small bores sized after printing where the fit requires it. Repeat lots follow the same files and scheduled releases, so parts arrive for the next assembly batch without a mould. DMLS AlSi10Mg is available for metal covers, with heat treatment, HIP or machining where required.

Typical parts
Equipment covers, mechanical stops, flexure springs
Key properties
Repeat files; bore sizing after printing; FDM ±0.25 mm or ±0.3%, whichever is greater
Material data
ASA: 98 °C HDT at 264 psi; Aluminum AlSi10Mg: ~99.85% density (EOS)
Materials
ASA (FDM)Aluminum AlSi10Mg (DMLS)
ABS-ESD7 guide and printed assembly fixtures on an electronics assembly line
ABS-ESD7 guide and printed assembly fixtures on an electronics assembly line

Jigs, fixtures and line parts

Production Tooling & Assembly Fixtures

FDM ABS-ESD7 makes static-dissipative guides and covers for electronics-assembly machines. Specify fill, layer height and build direction on the drawing, and first article inspection when required. Printed tooling also includes gear-clocking fixtures, FDM ABS assembly jigs, and torque-gauge fixtures for actuator testing. For automated handling, thousands of clip-on rims have been made from one unchanged file, giving fibre containers a rigid lip without a mould.

Typical parts
ESD guides and covers, assembly and test jigs, clocking fixtures, clip-on rims
Key properties
FDM ±0.25 mm or ±0.3%, whichever is greater; build direction to drawing
Material data
ABS-ESD7: 10⁴–10⁹ Ω surface and volume resistance
Materials
ABS-ESD7 (FDM)Accura 25 (SLA)Nylon PA12 (SLS)ABS (FDM)
Case Studies

Robotics Manufacturing Outcomes

Lighter finger segments, insert-bearing sensor kits, repeat actuator parts, subsea chassis, welding-cell hardware and ISE underwater vehicle mounts.

3D Printed Humanoid Robot Hand Parts: Finger Links, Grip Pads and Covers

Case study

3D Printed Humanoid Robot Hand Parts: Finger Links, Grip Pads and Covers

Humanoid-hand projects combine SLS structures, separate grip pads and protective covers. One finger design used about 40% less material by CAD-volume comparison; other work included shells, wrist housings and cable guides. The examples show how material choices, first samples and repeat batches fit together without tooling.

Key outcomes

  • Two finger segments: about 40% less CAD volume
  • Grip pads revised separately from structure
  • Protective shells and wrist parts in repeat batches
  • Samples and larger orders without tooling
Explore the humanoid-hand examples
Sensor Enclosure Kits in SLS PA12 With Heat-Set Inserts

Case study

Sensor Enclosure Kits in SLS PA12 With Heat-Set Inserts

Enclosures, lids, internal trays and mounts print as matched SLS PA12 kits. M4 and M5 heat-set inserts were specified by type, length, material and count, with light drawings locating the holes. A thicker tray went straight into the next lot as a revised file, while staged shipments supplied complete kits without tooling or a fixed design.

Key outcomes

  • Thousands of M4 and M5 inserts specified
  • Tray revised between lots without tooling
  • Kit-matched staged shipments
  • Production lot finished ahead of promise
Read the sensor kit case study
Exoskeleton Actuator Parts in SLS PA12: Handed Pairs and Shared Builds

Case study

Exoskeleton Actuator Parts in SLS PA12: Handed Pairs and Shared Builds

Small SLS PA12 travel stops and clamp plates can share builds in lots of dozens to hundreds, with flexible wire clips printed in TPU. Left- and right-hand parts stay paired, while unchanged files keep repeat orders consistent. Housing revisions and printed tooling run alongside the repeat parts, allowing development and production to continue without buying moulds.

Key outcomes

  • More than 3,000 printed parts
  • More than 1,000 stops in handed pairs
  • Median five business days from order to ready
  • Repeat lots without moulds
Read the actuator parts case study
3D Printed Subsea Electronics Chassis in SLS PA12

Case study

3D Printed Subsea Electronics Chassis in SLS PA12

Card brackets, support rails, cable posts and curved slide pads form a mixed electronics-chassis kit. Slotted holes let the pads adjust to the pressure housing bore, while printed part IDs help distinguish similar brackets. The same geometry was used across repeat orders, and one kit of over 100 pieces shipped in five business days.

Key outcomes

  • Repeat kits from unchanged geometry
  • Slotted holes adjust the assembly fit
  • Part IDs printed with the brackets
  • Large kit shipped in five business days
Read the subsea chassis case study
3D Printed Welding Robot Parts in FDM ASA and CF Nylon

Case study

3D Printed Welding Robot Parts in FDM ASA and CF Nylon

ASA equipment covers, Nylon 12 mechanical stops and carbon-fibre nylon flexure springs stay in production through small repeat lots. Released drawings specify the print recipe, with a sizing step for the spring's small bores. Each order carries the material, finishing requirements and scheduled release.

Key outcomes

  • Small repeat production lots
  • Print requirements recorded on drawings
  • Bore sizing specified after printing
  • Most dated lots shipped one to two days early
Read the welding robot parts case study
3D Printed Underwater Vehicle Hull Mounts for ISE

Case study

3D Printed Underwater Vehicle Hull Mounts for ISE

FDM ASA mounts follow the curved hull of International Submarine Engineering's Explorer autonomous underwater vehicle. Stored files made repeat parts possible, while multi-piece fibreglass plane extensions became single printed parts. Historical 2017–2018 quotes show lower costs and quoted lead times of one to two days for a mount and two to three days for plane extensions.

Key outcomes

  • 2018 mount quote: CAD $395.12
  • About 60% below reported mount fabrication cost
  • 2017 plane extension quote: CAD $216.44 each
  • Stored files for repeat parts
Read the ISE case study
Manufacturing Technologies

3D Printing Technologies for Robotics

Evaluate each process by geometry freedom, material options, and throughput so you can pick the right path from prototype to production.

Not sure which process fits? Our application engineers map your requirements to the right technology, material and finishing workflow before you commit to a build.

Chat with usCompare all technologies
Material Library

Materials for Robotics

Nylons, glass- and carbon-fibre composites, flexible TPU, rubber-like PolyJet Agilus30 and clear resin, chosen for fatigue life, stiffness per gram, grip and light transmission. Compare full properties on each material page.

Explore the complete material matrix. Compare certifications, mechanical properties and application fit across the full portfolio before locking your production material stack.

View material matrixGet an instant quote
Start a quote

Ready to Manufacture Your Robotics Parts?

Upload your CAD files for an instant quote or speak with our application engineers about your specific requirements.

  • Instant pricing with automated manufacturability analysis
  • Production workflows built for repeatable quality
  • Engineering support from prototype to production
Talk to an engineer

Create an account to upload CAD

STEP, STL, OBJ, 3MF and IGES supported

Manufacturing technologies
6
Engineering materials
50+
Part quantities
1-500+