2018
A cost-effective solution to automate CNC part handling using 3D printed custom jaws for Schunk compatible grippers.
3D Printing
Automation
OVERVIEW
One set of 3D printed jaws, multiple operations—designed for flexibility, speed, and precision.
To bridge the gap between CNC machining operations without manual intervention, we designed a custom set of 3D printed plastic jaws for a pneumatic gripper. This solution was tailored for a collaborative robot setup and enabled secure, multi-stage handling of complex parts while reducing cost, lead time, and tooling complexity.
Problem
Traditional Jaw Sets Were Inflexible and Costly
In automated CNC workflows, transferring parts between operations typically requires two different jaw configurations—one for the raw blank, and one for the semi-finished component. These jaws are usually milled from aluminum, which is time-consuming and expensive to produce, especially when only a few sets are needed. The lack of flexibility meant that any part design changes would render the jaws unusable. Manual jaw swapping also limited full automation.
Figure 1 – forces acting on the jaws during use
Solution
Flexible, Multi-Stage Jaw Design with Rapid 3D Printing
We replaced traditional metal jaws with a custom-designed PET-G plastic set, created specifically for a Schunk-compatible gripper.
Key features included:
Multiple grip interfaces: Flat, curved, and cylindrical profiles were combined into a single jaw set, allowing it to handle the part in all manufacturing stages—loading, repositioning, and unloading.
Quick production: A full set of jaws (100 x 40 x 15 mm) was printed in just two hours with no post-processing required.
Low cost: The manufacturing price was approximately 35 BGN (as of March 2023).
Design flexibility: If the part design changed, the jaws could be reprinted with minor model updates, making the setup ideal for low-volume production and prototyping.
Part protection: The PET-G material is softer than metal, preventing surface damage on delicate components.
For durability, we used 80% infill and aligned filament layers with expected force directions. To ensure precision, we added press-fit metal inserts (h7 tolerance) at the mounting points, maintaining tight alignment between the gripper and the robot arm.
Figure 2 – the same jaw set can be used for multiple operations
Conclusion
The 3D printed gripper jaws are definitely a success – we have been using them for months in our workshop with zero problems.
The printed jaws have been used in over 20,000 cycles in our workshop without failure. They enabled reliable part handling across multiple machining steps, supported automated workflows, and eliminated the need for manual jaw changes. For companies integrating collaborative robots and seeking affordable tooling for flexible manufacturing, 3D printed jaws offer a smart and scalable solution.
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.