Industrial Robot Safety
Compliance with ISO 10218 and ANSI/RIA R15.06 safety standards for industrial robotics applications and human-robot interaction.
Robotics SolutionsView All Industries
Accelerate Robotics Developmentwith Advanced 3D Printing
Forge Labs supports robotics teams with 3D printed end effectors, sensor mounts, structural frames, cable-management features, and low-volume deployment parts. We help engineers cut iteration time while preserving the stiffness, weight targets, and assembly integration that advanced robotic systems demand.
Prototype Lead Time
24-72hrs
Weight Reduction
60%
Design Iterations/Week
5+
Custom Materials
15+
Robotics Overview
Revolutionizing Robotic Component Manufacturing
Modern robotics programs demand lightweight, high-strength parts with integrated routing, custom interfaces, and rapid revision cycles. Forge Labs uses additive manufacturing to help robotics companies move from concept hardware to functional deployment parts without tooling overhead, supporting everything from warehouse automation to drones and mobile platforms.
Where additive creates leverage
Built for faster robotics decisions
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
- Design freedom for integrated channels and lattice structures through advanced additive manufacturing solutions tailored for robotics applications.
- Accelerate development timelines and compress design cycles, enabling faster innovation and reduced time-to-market.
- Lightweighting without sacrificing strength or performance through advanced additive manufacturing solutions tailored for robotics applications.
- Eliminate expensive tooling requirements, reducing upfront investments and enabling economical low-volume production.
- Functional prototypes for real-world performance testing through advanced additive manufacturing solutions tailored for robotics applications.
- Custom geometries impossible with traditional manufacturing through advanced additive manufacturing solutions tailored for robotics applications.
Quality and compliance
Production workflows for functional robotics hardware
Robotics parts have to balance stiffness, weight, cable routing, wear resistance, and fast revision cycles. We pair those requirements with material data and production workflows that support functional testing.
Performance Testing
Comprehensive mechanical testing including load, fatigue, and environmental validation for robotic operating conditions.
Material Specifications
Engineering-grade materials with documented mechanical properties, wear resistance, and long-term durability data.
Rapid Iteration Capability
Proven design-to-deployment workflow enabling multiple prototype iterations within days for accelerated development cycles.
Manufacturing Capabilities
Capabilities Engineered for Robotics
From concept models to production-intent hardware, each workflow is tuned for the precision, repeatability, and engineering confidence that robotics teams demand. Our capabilities span rapid prototyping with sub-millimeter accuracy, complex geometry optimization for weight reduction, and low-volume production with full material traceability — giving engineering teams the speed to iterate faster and the data to qualify parts with confidence.
Custom End Effectors & Grippers
Design and manufacture application-specific end effectors with integrated pneumatic channels, custom grip geometries, and lightweight materials. Our technologies enable rapid prototyping of gripper designs optimized for specific tasks, with the ability to iterate quickly based on real-world testing and performance requirements.
Insight 1
Custom grip geometries
Insight 2
Integrated pneumatic channels
Weight reduction
up to 60%
Insight 4
24-hour prototype turnaround
Relevant technologies
Stereolithography (SLA)/Fused Deposition Modeling (FDM)/PolyJet Matrix (PolyJet)
Material options
High Temperature Resin/Accura 25/Accura Xtreme White 200/Accura ClearVue
Custom End Effectors & Grippers
Sensor & Camera Mounting Systems
Produce lightweight, integrated mounting solutions for vision systems, LIDAR, and sensor arrays. Create custom housings with precise optical alignment features, integrated cable management, and environmental protection while maintaining minimal weight impact on robotic systems.
Insight 1
Precise optical alignment
Insight 2
Integrated cable management
Insight 3
Environmental protection
Insight 4
Minimal weight impact
Relevant technologies
Selective Laser Sintering (SLS)/Fused Deposition Modeling (FDM)/Stereolithography (SLA)/Direct Metal Laser Sintering (DMLS)
Material options
Sensor & Camera Mounting Systems
Lightweight Structural Frames
Engineer optimized structural components for drones, autonomous robots, and mobile platforms using topology optimization and lattice structures. Achieve maximum strength-to-weight ratios while incorporating mounting points, cable routing, and component integration in single-piece designs.
Insight 1
Topology optimization ready
Insight 2
Maximum strength-to-weight ratio
Insight 3
Single-piece assemblies
Insight 4
Integrated mounting systems
Relevant technologies
Selective Laser Sintering (SLS)/Fused Deposition Modeling (FDM)/Stereolithography (SLA)/Direct Metal Laser Sintering (DMLS)
Material options
Lightweight Structural Frames
Functional Prototypes & Testing
Our technologies enable production of parts not just for visual validation, but for real-world performance testing and deployment. Test mechanical properties, thermal performance, and functional integration before committing to production tooling or design finalization.
Insight 1
Real-world performance testing
Insight 2
Mechanical property validation
Insight 3
Thermal performance testing
Insight 4
Functional integration verification
Relevant technologies
Stereolithography (SLA)/Fused Deposition Modeling (FDM)/PolyJet Matrix (PolyJet)/Selective Laser Sintering (SLS)
Material options
High Temperature Resin/Accura 25/Accura Xtreme White 200/Accura ClearVue
Functional Prototypes & Testing
Production Tooling & Assembly Fixtures
Create custom jigs, fixtures, and assembly tools for robotic manufacturing and calibration. Design specialized tooling for robot assembly lines, testing fixtures for quality control, and alignment tools for precision assembly operations.
Insight 1
Custom assembly solutions
Insight 2
Precision alignment tools
Insight 3
Quality control fixtures
Insight 4
Cost-effective tooling alternative
Relevant technologies
Selective Laser Sintering (SLS)/Multi-Jet Fusion (MJF)/Direct Metal Laser Sintering (DMLS)/Fused Deposition Modeling (FDM)
Material options
Production Tooling & Assembly Fixtures
Cable Management & Enclosures
Design integrated cable management systems with internal routing channels, snap-fit connections, and protective enclosures. Create rugged, test-ready chassis and protective housings for electronic components in demanding robotic environments.
Insight 1
Internal routing channels
Insight 2
Snap-fit connections
Insight 3
Rugged environmental protection
Insight 4
Integrated design solutions
Relevant technologies
Selective Laser Sintering (SLS)/Fused Deposition Modeling (FDM)/Stereolithography (SLA)/Direct Metal Laser Sintering (DMLS)
Material options
Cable Management & Enclosures
Custom End Effectors & Grippers
Case Studies
Robotics Manufacturing Outcomes
Examples covering end effectors, structural frames, and integrated assemblies for autonomous systems, warehouse robots, and drones.
Case Study
Autonomous Mobile Robot End Effector System
Developed custom gripper system for warehouse automation robot, integrating pneumatic channels, force sensors, and adaptive grip geometry. Achieved 50% weight reduction compared to machined alternative while improving grip versatility and reducing assembly complexity.
Key outcomes
50% weight reduction achieved
Integrated pneumatic channels
Adaptive grip geometry
75% faster prototype iterations
Case Study
Drone Racing Frame Optimization
Engineered lightweight carbon fiber reinforced frame for competitive drone racing, using topology optimization to achieve maximum strength-to-weight ratio. Reduced frame weight by 40% while improving crash resistance and integrating cable management systems.
Key outcomes
40% frame weight reduction
Improved crash resistance
Integrated cable management
Competition-ready performance
Material Library
Robotics-Grade Materials
Qualified materials selected for performance, certification requirements, and repeatable production in robotics environments.
SLS
Nylon PA12
Robotics grade
High-strength polymer
- Structural robot components
- Excellent wear resistance
- Chemical resistance
View Material Details
FDM
Carbon Fiber Nylon
Robotics grade
Lightweight composite
- High-performance frames
- Superior mechanical properties
- Excellent dimensional stability
View Material Details
SLS
Accura ClearVue
Robotics grade
Transparent resin
- Optical components and sensors
- High-detail resolution
- UV-stable formulation
View Material Details
DMLS
Aluminum 6061
Robotics grade
Structural metal alloy
- Rigid mounting brackets
- Excellent strength-to-weight ratio
- Good corrosion resistance
View Material Details
SLS
TPU
Robotics grade
Flexible polymer
- Grippers and shock absorbers
- Excellent tear resistance
- Compliant mechanisms
View Material Details
SLS
Glass Filled Nylon
Robotics grade
Reinforced polymer
- Enhanced stiffness and strength
- Dimensional stability
- Industrial grade performance
View Material Details
Explore Our Complete Material Matrix
Compare certifications, mechanical properties, and application fit across our full portfolio before locking your production material stack.
Manufacturing Technologies
Proven Technologies for Robotics
Evaluate each process by geometry freedom, material options, and throughput so you can pick the right path from prototype to production.
Selective Laser Sintering (SLS)
Build Volume340 × 340 × 600 mm (13.4 × 13.4 × 23.6 in)
Layer Height60 - 120 microns
Materials4 available
No Support StructuresCost-Effective for Complex Parts+4 more
Learn More
Fused Deposition Modeling (FDM)
Build Volume914 × 609 × 914 mm (36" × 24" × 36")
Layer Height127 - 330 microns
Materials7 available
Large-Format PrintingCost-Effective Manufacturing+5 more
Learn More
Stereolithography (SLA)
Build Volume1500 × 750 × 550 mm (59 × 29.5 × 21.7 in)
Layer Height0.025 - 0.150 mm
Materials5 available
Highest DetailSmooth Finish+2 more
Learn More
Direct Metal Laser Sintering (DMLS)
Build Volume380 × 284 × 380 mm (15 × 11.2 × 15 in)
Layer Height0.02 - 0.06 mm
Materials6 available
Fully Dense Metal PartsComplex Geometries+5 more
Learn More
Need help selecting the best process?
Our application engineers can map your requirements to the right technology, material, and finishing workflow before you commit to a build.
Start a quote
Ready to Transform Your Robotics Manufacturing?
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
Upload your CAD file
STL, STEP, OBJ, 3MF supported
Instant pricing and manufacturability feedback
- 6
- Manufacturing technologies
- 50+
- Engineering materials
- 1-500+
- Part quantities