3D Printing for Custom Machinery & Automation Technology
Iterative prototypes and series components for customer-specific systems – from the first CAD idea to the assembled unit in a few business days. Manufactured locally in Stuttgart.
Why additive manufacturing in custom machinery?
Custom machinery means: every system is a one-off. Modification loops on machine frames, retrofits on existing lines or system-specific sensor positioning are barely economical to achieve with classic manufacturing processes – minimum quantities, long lead times and high tooling costs stand in the way.
With industrially calibrated FFF 3D printing, tooling costs disappear entirely. Every geometry is economical from unit 1. Geometry corrections are implemented within hours, the reprint follows the next day.
- No minimum quantities – unit 1 is profitable
- Lead time typically 2–3 business days from an approved CAD file
- Geometric freedom: undercuts, internal channels, complex contours
- Direct feedback on constructive unprintability
- Material change with no setup cost between orders
from an approved file
checked with a digital caliper
incl. CF composite, elastomers, tribology
Typical Parts in an Automation System
The following components are manufactured regularly for custom machinery builders and integrators. All parts are also available in small batches after technical review.
Sensor Brackets
Mounting angles, sensor carriers and positioning plates for photoelectric sensors, inductive switches, machine vision systems and distance sensors. Fitted to the millimeter on existing machine profiles.
Cable Routing & Wire Holders
Cable ducts, clamp and clip systems for structured cable routing on machine frames and robot circuits. Connector assignments and cross-sections are designed per part.
Control Cabinets & Covers
IP-protected housings for evaluation electronics, PLC expansion modules and power supplies. Designed to fit DIN rails or profile rails precisely, cable entries and mounting holes integrated into the print.
Grippers & End-of-Arm Tooling
Custom gripper fingers, suction cup mounts and tool holders for collaborative robots (UR, KUKA, Fanuc). Weight-optimized structures with integrated air channels for vacuum gripping systems.
Fixtures & Clamping Devices
Mounts, templates and inspection fixtures for assembly and testing processes. Complex-contoured shaped parts for workpiece alignment that would be uneconomical with CNC.
Materials for the Automation Environment
Depending on installation environment, temperature load and mechanical requirement, different materials are used. All materials are directly calculable in the online calculator.
ASA (UV-stable)
Ideal for outdoor mounting and industrial halls with UV exposure. Dimensionally stable up to 95 °C, weather-resistant, good post-processability (sanding, painting).
- HDT up to ~95 °C
- UV- and weather-resistant
- Paints well
PA-CF (Carbon Fiber)
Highest specific stiffness in the FFF portfolio. For load-bearing brackets, grippers and fixtures under continuous load. Steel nozzle required.
- Tensile strength ~100 MPa
- HDT up to ~180 °C
- Low weight at high stiffness
PC (Polycarbonate)
For control cabinets and covers in thermally loaded areas. High impact resistance, up to 135 °C, optionally transparent for viewing windows.
- HDT up to ~135 °C
- Extremely impact-resistant
- Optionally transparent
iglidur i180
Self-lubricating plain bearing material from igus for linear guides, shaft bearings and gears. No oil, no grease – low-maintenance operation even in dirty environments.
- Continuously low-maintenance (no lubricant)
- Wear resistance ~10× better than PA
- igus-certified
TPU 85A (soft)
Flexible damping elements, protective covers and cable grommets. Shore 85A – soft enough for buffers, firm enough for shape-stable hoses and sealing lips.
- Shore 85A – very flexible
- Abrasion- and tear-resistant
- Usable up to ~80 °C
PAHT-CF (up to 200 °C)
For components directly at heat sources like motors, presses or ovens. Carbon-fiber-reinforced high-temperature PA with up to 200 °C HDT under continuous load.
- HDT up to ~200 °C
- Tensile strength ~120 MPa
- Dimensionally stable under thermal load
→ All high-performance materials at a glance · → Complete material range
Seamless Integration into Existing Automation Environments
Additive manufacturing doesn't end at the part. Components for automation systems need to fit existing system architectures – mechanically, electrically and logistically.
As a mechanical engineering technician (Bachelor Professional), parts are assessed from an engineering standpoint: wall thicknesses for threaded inserts (M3–M8), fit dimensions for bearing seats and press-fit bushings, and tolerance chains for assembly units are designed to fit the material and process.
- Threaded inserts (Heli-Coil, heat-set threads) can be added afterward
- Mounting on aluminum profile systems (Item, Bosch Rexroth) accounted for
- DIN rail clips and rail mounts can be integrated
- Protection classes IP40–IP54 through matching housing geometry and sealing groove
- Cable feedthroughs, strain reliefs and hook-and-loop channels in the print
- Design feedback for PLC-adjacent mounting on request
Every inquiry is assessed from an engineering standpoint. Feedback on wall thicknesses, orientation and tolerances comes at no extra charge. More about our services →
From Inquiry to Delivered Component
Submit File or Description
Upload STL or STEP via the calculator or send a project description via the contact form. Sketches, photos of existing components or dimensions via email also work as a starting point.
Technical Review & Quote
Wall thicknesses, printability and material suitability are checked. For standard geometries, the calculation follows instantly in the browser; for complex assemblies, you'll receive a binding quote within 24 hours.
Manufacturing & Quality Control
Printing on calibrated industrial hardware with a material-specific profile. Visual inspection, dimensional check with a digital caliper (0.01 mm) and, if needed, post-processing (support removal, thread cutting).
Delivery from Stuttgart
Shipping via DHL/DPD or courier delivery in the Stuttgart area. For local custom machinery builders, on-site installation consultation is also possible.
Frequently Asked Questions – 3D Printing in Custom Machinery
How quickly can custom machinery components be manufactured at 3D Fabrikant?
Standard lead time for custom machinery components is 2–3 business days from an approved CAD file (STEP or STL). Express manufacturing in 24–48 hours is possible for simpler geometries on request. 3D Fabrikant manufactures locally in Stuttgart-Zuffenhausen – no shipping through subcontractor networks, direct communication with the mechanical engineering technician.
Which materials are best suited for parts in an automation system?
Material choice depends on installation environment and load case: ASA for UV-exposed outdoor mounts and weather exposure; PA-CF for load-bearing brackets and grippers (tensile strength ~100 MPa, HDT ~180 °C); PC for control cabinets with heat load up to 135 °C; iglidur i180 for low-maintenance plain bearings and linear guides without lubrication; TPU 85A for damping elements and flexible cable routing; PAHT-CF for engine-bay-adjacent components up to 200 °C.
Can 3D printed parts be mounted directly on Siemens S7 / Beckhoff controllers?
Yes. Brackets, covers and cable routing for PLC systems (Siemens S7-1200/1500, Beckhoff CX, Schneider M241) are manufactured regularly. Mounting on DIN rails (EN 60715 TH35) and rail clips can be integrated into the design. Cable entries with strain relief, M3–M8 threaded inserts (Böllhoff Ensat / Heli-Coil) and labeling fields can be planned into the print.
Are 3D printed grippers suitable for collaborative robots (cobots)?
Yes, for light to medium loads (< 5 kg payload), 3D printed gripper fingers and EOAT mounts are regularly used for UR3/UR5/UR10, KUKA LBR iiwa and Fanuc CR series. Material PA-CF or PC-CF for rigid structures; TPU 85A for soft gripper pads. ISO 9283-compliant load data isn't guaranteed – safety-relevant cobots require approval from the integrator.
What IP protection class can 3D printed housings achieve?
With design measures (a circumferential sealing groove for an O-ring or foam seal, matching housing lid geometry), suitable materials (PETG, ASA, PC) can achieve protection classes up to IP54. IP65/IP67 typically require additional sealing measures and potting, which 3D Fabrikant coordinates on request. Standards-compliant IP testing per IEC 60529 isn't a standard service – available on request.
More questions → Full FAQ page with 26 questions
Calculate your next machine part online
Upload STL or STEP – instant indicative price based on your parameter choices. Binding quote after technical review.