Integrated Design and Programming of a KUKA Industrial Robot for 3D Printing

Description

This project develops an integrated mechanical design and control framework to convert a KUKA industrial robot (KR 4 AGILUS) into a robotic 3D printing system. It combines nozzle and end-effector integration with motion programming, trajectory planning, and toolpath generation for extrusion-based additive manufacturing, including kinematic analysis and implementation using KUKA Robot Language. Standard G-code is translated into robot-compatible commands with coordinated control of TCP motion and process parameters. Simulation and offline programming tools, such as RoboDK, are used for trajectory validation and motion analysis to ensure smooth, continuous, and geometrically accurate deposition. The influence of velocity profiles, path blending, and interpolation accuracy on printing quality and dimensional precision is evaluated, demonstrating the feasibility of transforming an industrial manipulator into a reliable robotic additive manufacturing platform.