ROBOTIC ADDITIVE MANUFACTURING FOR COMPOSITES AND THERMOPLASTICS

Caracol’s extruders process composite fiber-reinforced thermoplastic pellets, with models tailored to different manufacturing needs—balancing performance, quality, and cost-efficiency.

• xHigh Flow (xHF): Compact, durable, and Caracol’s highest-throughput extruder, enabling precise bi-material printing for large-scale, advanced industrial applications.
• High Flow (HF): Robust and fast, ideal for reducing print times while maintaining material versatility and quality.
• High Versatility (HV): Flexible and adaptable across a wide range of industrial applications.
• High Accuracy (HA): Lightweight and precise, perfect for fine detailing, quality finishes, and agile movement.

Leveraging the flexibility of the 6+ axes movements, robotic arms allow Heron AM to manufacture parts with very complex geometries, including non-planar tool paths, and unconventional slicing at different angles such as 45° or 60. Robotics also allows to modularly set up the system with different arm sizes to satisfy specific needs on applications or production area. Furthermore, arms can be extended on the x-axis with a rail or on the y-axis adding a plinth. To provide the best automation solution, Heron AM can be setup with robots from KUKA to FANUC and ABB.

The Heron AM platform features a user-friendly HMI and a self-standing Control Unit for precise extruder and process control, as well as efficient side machine operations. For enhanced functionality, the system can include a dedicated screen for smart monitoring and IoT integration.

To ensure modularity and flexibility, Heron AM platforms are equipped with the Caracol Control Cabinet, a centralized unit compatible with multiple, industrial end-effectors through plug-and-play logic. This enables customization for diverse applications with ease.

Caracol developed its Eidos Manufacturing Software Suite, with years of experience in Design for robotic LFAM, slicing strategies, and robotic cinematics. The software suite completes Caracol’s LFAM turnkey hardware, ensuring full control and flexibility on the process.

Eidos Builder enables easy machine programming and parameter setup through a user-friendly interface. It lets users simulate and select build strategies – planar, angled, or non-planar – for precise control over complex tool paths.

Eidos Nexus enhances robotic platforms with intelligent automation features, collecting and analyzing data to optimize performance. It maximizes efficiency and quality, empowering you to effectively scale your industrial production capabilities.

The printing bed is key to successfully print parts. Caracol has developed several models to fit all needs, customizable in terms of size.
The aluminum frame structure with interchangeable top panels, is a convenient and flexible set up. With a simple brim or raft it ensures stability throughout the job. With the simple stainless-steel bed, high rigidity and planarity, anti-corrosion, and durability are guaranteed.
The patented automatic bed for unmanned part clamping and unloading was designed by Caracol to guarantee automated production with great part stability. The aluminum slats structure allows mechanical gripping of the first layer. Rotating at the end of each cycle and releasing the printed part autonomously, this printing bed is ideal for continuous production.

The direct and continuous supply of material is possible thanks to the automated material feeding system, developed by Caracol. A drying unit is connected to the extruder to input pellets during the whole printing cycle, avoiding manual operations that could stop the machine’s job.
Pellets and shreds are stored at the right humidity and temperature and dried for best performance and quality. Its capacity of 50-80 Kg (110-176 lb) can be extended with direct connection to a bigger storage or with multiple material feeding units, to facilitate production-continuity for unlimited hours.

Perimetral protections are needed to operate with the optimal printing conditions and safety. Enclosures allow to control environmental parameters, such as temperature and humidity, and track them to guarantee process repeatability and quality. Customers can opt for different configurations: open air Safety Light Curtains and Protective Cages; Advanced Enclosure, developed to control all environmental parameters, monitor printing, guarantee safety, process repeatability, and quality; Portable Container Unit, to set up manufacturing of parts in any location.

Thanks to its dedicated automation and control suite, Heron AM supports an automatic tool changer compatible with multiple industrial end-effectors. This enables seamless switching between Caracol’s extruders or a milling head within the same production cycle—boosting versatility, reducing downtime, and maximizing efficiency.