Discover how 3D printing helped build humanoid robot parts with lightweight structures, fast turnaround, and exhibition-ready finishes.
Introduction: Powering the Future of Humanoid Robotics
Humanoid Robots (Shanghai) is dedicated to developing next-generation humanoid robots.
For the WAIC 2024 World Artificial Intelligence Conference, they needed to showcase a full-scale prototype robot whose parts had to be lightweight, heat- and wear-resistant, rigid, and aesthetically appealing — all under an extremely tight schedule.
By collaborating with Unionfab, Humanoid Robots successfully produced the robot’s leg shells and soles using industrial-grade 3D printing technology.
This solution not only ensured strength and functionality but also significantly shortened production time, delivering eye-catching design highlights for the exhibition.
The Challenge: Building High-Performance Humanoid Robot Components
The project presented several critical challenges that traditional manufacturing struggled to meet:
● Rapid Delivery: Completing complex structural parts within an extremely short timeframe.
● Multifaceted Performance: Balancing high strength, lightweight, heat resistance, and wear resistance.
● Aesthetics & Assembly: Ensuring parts met exhibition-level aesthetic requirements and reliable assembly.
● Complexity & Time Constraints: Traditional manufacturing methods couldn't handle the structural complexity or the urgent timeline.
Traditional machining couldn’t meet these goals. 3D printing changed everything.
Unionfab‘s 3D Printing Solutions
Humanoid Robots fully leveraged Unionfab's design freedom and flexible manufacturing capabilities offered by 3D printing.
Key Technology Choices for High-Performance Robot Parts:
SLS Nylon for Load-Bearing Components: We utilized SLS Nylon 3D printing for the robot's load-bearing parts (leg shells), providing strong rigidity, good dimensional stability, and durability for selected load-bearing robot parts.
TPU for Flexible & Wear-Resistant Parts: TPU material was chosen for 3D printing the shoe soles and flexible cushioning elements, providing excellent wear resistance, elasticity, and shock absorption. It is well-suited to robotic foot components and flexible robot parts.
Optimized for Performance & Production:
Structural Optimization (Topology Optimization for Robotics):
Topology optimization was employed to reduce weight while maintaining strength. This is crucial for lightweight robot design.
Integrated wiring channels and cooling vents directly into the part structure, significantly reducing subsequent assembly complexity – a key benefit of 3D printed complex geometries.
Post-Processing & Aesthetics (Exhibition-Ready Finish):
Surface painting and fine polishing ensured an exhibition-grade appearance.
Achieved consistent surface finishes between flexible and rigid parts, creating a cohesive overall look.
Production & Delivery (Accelerated Manufacturing for Robotics):
From design file to part delivery within a short turnaround time, depending on geometry, finishing, and production scheduling.
Our online platform provided instant pricing and delivery feedback, vastly improving efficiency for on-demand robot part production.
Remarkable Results: Humanoid Robot Success at WAIC 2024
The collaboration between Humanoid Robots and Unionfab yielded outstanding results:
Shorter Delivery Time: Assembly was completed ahead of the exhibition deadline, supporting a fast prototyping workflow.
Reduced Weight: Helped improve movement flexibility and agility for the humanoid robot prototype.
Improved Wear & Heat Resistance: Supported the project's functional and durability requirements for prototype display and testing.
Strong Exhibition Impact: Helped create a strong visual impact at the exhibition through the robot's design and finish.
Flexible Scalability: Future iterations and modifications can be quickly reproduced and improved, highlighting the benefits of additive manufacturing for robotic development.
Material Spotlight: The Power of PA12 Nylon & TPU for Robotics
The combination of these advanced materials was key to the project's success:
PA12 Nylon (SLS Nylon for Robots):
Properties: High rigidity, heat resistance, and impact resistance.
Application: Well-suited to load-bearing casings and structural components in robotics.
TPU (Flexible TPU for Robotics):
Properties: Flexibility, wear resistance, and fatigue resistance.
Application: Well-suited to cushioning elements and shoe soles, helping improve impact absorption and movement comfort.
By combining these two materials, Unionfab ensured both strength and comfort, while maintaining consistent surface aesthetics and quality across all parts, crucial for functional and aesthetic robot design.
Technology Selection & Precision: Unionfab's Advanced 3D Printing
Printing Process (SLS 3D Printing for Robotics): Unionfab utilized SLS (Selective Laser Sintering) technology to produce complex structures for the robot's nylon leg shells and flexible TPU shoes. This ensured precise dimensions and robust mechanical performance.
Part Accuracy: Delivered dimensional accuracy suitable for complex assembly and prototype integration.
Design Optimization (Integrated Design for Robotics): Topology optimization helped reduce weight, while integrated design lowered part count and assembly complexity.
Post-Processing (Exhibition-Grade Finish): Painting, polishing, and surface encapsulation provided a display-ready appearance, ensuring both aesthetic appeal and enhanced durability for the parts.
Customer Testimonial
“Unionfab’s 3D printing capabilities let us complete complex robotic components in record time. The results exceeded our expectations — strong, lightweight, and visually impressive.
Our robot gained huge attention at WAIC for its futuristic design.”
— R&D Director, Humanoid Robots (Shanghai)
Why Choose Unionfab for Robotic 3D Printing
High-Performance Materials: Nylon PA12 & TPU for strength, flexibility, and durability
Advanced Processes: SLS, SLM, MJF, FDM, PolyJet, CNC, and more
Precision Manufacturing: ±0.2 mm tolerance for complex assemblies
Rapid Prototyping to Small-Batch Production: 1 to 1000 parts
800+ Industrial 3D Printers: Ensuring speed, scale, and reliability
Whether you’re building humanoid robots, autonomous vehicles, or robotic grippers, Unionfab helps you turn ideas into functional, production-ready parts.
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