Digital workflow for media-free grippers: flexible gripping technology from 3D printing

Challenges

Gripping processes in automation often require the use of external media such as compressed air or hydraulics. This leads to additional energy requirements and increased maintenance costs. At the same time, there is a growing need for flexible gripping systems that can be quickly adapted to new object geometries.

Solutions

At SPS Nuremberg 2025 and Formnext 2025, the Institute of Production and Information Technology (IPI) at Kempten University of Applied Sciences presented a media-free gripper that does not require external energy sources. The additively manufactured gripper is based on a self-locking mechanism that is activated solely by the movement of the robot. The monolithic design uses the principle of Compliant Mechanisms, which enables movements through elastic deformations instead of classic joints.

For the trade fair exhibit, the gripper was mounted on the robot using quick-change technology from EOS. This allowed various object-specific grippers to be exchanged directly on site and the potential of the system to be demonstrated.

The gripper weighs around 50 g and has already been tested for objects weighing up to 100 g under dynamic movements. It is manufactured using SLS 3D printing and enables the economical production of small quantities. The concept is currently in the patent process.

Digital workflow for rapid development

The trade fair exhibit focused on the digital workflow for object-specific gripper customization. This is implemented using the Synera platform.

First, the geometric parameters of the target object are automatically recorded. On this basis, the parametric CAD model of the gripper is iteratively adapted until an optimal fit is achieved. It is then prepared for additive manufacturing and printed using the SLS process.
The finished gripper is quickly ready for use on the robot: the printed gripper can be assembled and tested immediately using EOS quick-change technology.
This process significantly reduces development times and enables quick adaptations to new object shapes.

Outlook

Further tests on load-bearing capacity and dynamic loading are planned.

In the future, the system will be suitable for flexible assembly scenarios and small series production.

A video about the trade fair appearance at SPS Nuremberg 2025 and how the gripper works is available on YouTube: Aftermovie SPS 2025

Further information