Leveraging Additive Manufacturing in Industry to Create Enhanced-Performance Components

AM technology enables the production of complex structures layer-by-layer, thus transforming traditional manufacturing methods and offering unprecedented design freedom and material efficiency. This research aims to bridge the gap between AM's theoretical capabilities and practical applications in the robotic and industrial fields, where AM can reduce mechanical complexity, optimise performance, and increase part reliability. In particular, the potential of additive manufacturing (AM) in robotics is explored, focusing on two key innovations: monolithic mechanisms with compliant joints and non-planar additive manufacturing. Monolithic mechanisms, manufactured as single, integrated parts, eliminate the need for assembly and increase the durability of robotic components. Compliant joints within these mechanisms enable movement through elastic deformation of the part itself, enhancing their robustness and reducing the need for maintenance. Non-planar AM further contributes to this field by allowing 3D layer paths, minimising the staircase effect and enhancing the surface quality and practical performances. First, this thesis provides a detailed review of the current state of monolithic mechanisms with compliant joints and the advances in non-planar additive manufacturing. In pursuit of practical applications, this work presents the design and development of two additively manufactured monolithic robotic components: a compliant joint gripper and a robot with delta kinematics. These designs showcase the benefits of AM in producing simple, efficient, and lightweight components tailored for industrial applications. Furthermore, the thesis introduces an innovative slicing algorithm for non-planar AM designed for desktop machines. This new slicing methodology optimises layer orientation along curved paths, improving part surface finish through slices from the intersection with the model to be printed to accurately reproduce the model top surfaces while avoiding collisions. By integrating advanced design and manufacturing techniques, this thesis demonstrates AM's transformative impact on robotic design, potentially redefining standards in high-performance, customised parts in robotic and industrial fields.