2024
How we scaled FDM printing into a reliable, lights-out production system with custom robotics and software.
3D Printing
Automation
Overview
Our in-house robot, paired with custom software and high-speed printers, allows us to run continuous manufacturing without human intervention.
At DHR Engineering, 3D printing has always played a key role in our work. We use it daily to create custom jigs, alignment tools, brackets, and fixtures that support our automation systems. These parts help us reduce lead times, speed up R&D, and deliver faster results to our clients in the CNC machining and industrial automation space.
However, as our business grew, so did our printing needs. We found ourselves printing hundreds of functional parts each week, often on tight deadlines. Our previous system—based on a small number of desktop printers operated manually—could no longer support the level of output and reliability we required.
We realized that 3D printing had become a critical step in our operations. In order to continue scaling, we needed to apply the same automation mindset that we bring to our client projects. This is how our automated 3D printing farm began. What started as a 20-printer setup has now evolved into a fully autonomous manufacturing cell with 44 machines, centralized scheduling, robotic handling, and advanced error management.
This article walks through the entire process, from the initial problem to the results we achieved, and outlines what we are building next.
Our custom-built robot handles bed loading and unloading across the entire FDM farm. Designed in-house, it’s the core of our fully automated 3D printing system.
Problem
Manual Printing Was Slowing Down High-Value Projects
Before we built the automated system, our printing process looked like many other engineering teams. We had a group of desktop 3D printers operated manually by our staff. The printers were not connected to any centralized system. We queued jobs by hand, monitored print status manually, and often had to intervene during or after prints. If a bed needed to be changed or a filament ran out, a team member had to stop what they were doing and take care of it.
This led to several issues:
Printers would stop unexpectedly, and we would not notice for hours.
Print beds had to be unloaded and reloaded by hand, including late at night or on weekends.
Engineers lost valuable working time managing basic printer operations.
We could not run multi-material or flexible filament prints without constant supervision.
Scaling our output meant hiring more people rather than improving the system.
These problems directly affected our ability to deliver on time. Many of the prints we produced were used in mission-critical systems for CNC tending, robotic arms, and tool changers. Delays in printing meant delays in the entire automation workflow. In some cases, waiting for a single jig or bracket delayed client projects worth hundreds of thousands of dollars.
We knew that the only way to solve this problem was to design a fully automated print system that could run continuously, with minimal oversight.
An earlier stage of the farm, running 20 printers. This was our first fully functional setup with automated bed handling and centralized control.
The Build
Designing a Scalable, Automated 3D Printing Farm
We started by defining exactly what we wanted the system to achieve. It had to be fast, reliable, scalable, and easy to operate. We also wanted to support a wide variety of print materials, including TPU, which is commonly used in flexible grippers and mounts.
Printer Selection
We chose Bambu Lab printers for their speed, reliability, and support for multi-material printing. The combination of fast printing and consistent quality made them the right foundation for our farm.
Robotic Bed Handling
The first step was automating the most repetitive and time-consuming task: bed loading and unloading. We built a custom robot, developed entirely in-house, that takes care of this process.
The robot picks up completed beds and places them on custom-designed shelves.
It then loads a new, clean bed into the printer and signals the system to begin the next job.
All movements are pre-calculated and calibrated for each machine position.
This robot now handles dozens of prints per day across 44 machines. It works consistently, without breaks, and can be expanded easily as we add new printers.
Scheduling and Control Software
Next, we developed our own automation software. This system coordinates everything in the farm.
It assigns print jobs to available machines.
It monitors print status and detects failures or interruptions.
It automatically reschedules failed jobs and sends alerts if needed.
It handles multi-material print queues and adapts print speeds for different filaments.
The software is tightly integrated with our robotic system, so each completed job is removed and a new one starts without any human involvement. The system runs in full “lights-out” mode during nights and weekends.
Scalability by Design
We wanted to make sure the system could grow with our business. Every part of the infrastructure is modular. New machines can be added quickly without changing the robot layout or software architecture. This allowed us to expand from the initial 20 printers to 44, and we are currently scaling to 200.
New Features and Demonstrations
Recently, we introduced a new automation feature: filament swap. We demonstrated a working system with three printers where filament changes are handled automatically. This was a proof-of-concept for a much larger system that will soon be integrated into the entire farm.
We are also developing a custom filament storage system. It will help us store, track, and deliver the right materials to each printer without manual effort.
With more machines, shelving, and storage racks added, this setup paved the way for scaling beyond 40 printers.
Results
Better Performance, Faster Prototypes, and Lower Costs
Since launching the automated 3D print farm, we have seen significant improvements across all areas of our business.
Printer uptime has increased dramatically, with machines running more than 95% of the time.
One operator can now manage the entire farm with just a few hours of maintenance per week.
Parts come out more consistently, with fewer failures and less waste.
We are able to run complex multi-material and TPU jobs unattended.
The system has removed one of the biggest bottlenecks in our workflow. 3D printing is no longer something we need to manage—it is something that actively supports our growth. We can now deliver faster, experiment more often, and build better systems for our clients.
Most importantly, the print farm is no longer a fixed capacity. It is a dynamic, scalable manufacturing platform that we fully control and continue to improve.
What Comes Next
We are currently expanding the farm toward 200+ machines and preparing for a full-scale rollout of our filament handling system. Every new feature is developed with one goal in mind: full autonomy.
Our long-term vision is to treat 3D printing the same way we treat industrial machine tools: predictable, efficient, and fully automated. We believe this is the future of additive manufacturing, and we are building it ourselves—one layer at a time.
If you're facing throughput challenges or planning your next production ramp — let’s talk. We work with hardware teams who build things that matter, and need their automation to move fast and perform flawlessly.