Case Study: AIRSKIN (Blue Danube Robotics) achieves same-day, high-precision custom parts with Carbon

Enabling Safe Human and Robot Collaboration with Blue Danube Robotics

AIRSKIN, the patented pressure‑sensitive robot "skin" from Blue Danube Robotics, needed easy‑to‑clean, low‑volume customized elastomeric parts (pads, wiring harnesses, brackets) that could achieve very thin sensor walls and precise fits. Previous approaches (open‑cell foam, roto‑cast, SLS) lacked elasticity, left dust residue, and slowed iteration. To address this, AIRSKIN turned to Carbon, using the Carbon DLS™ process and Carbon M2 printer and materials to meet its accuracy and customization requirements.

Using Carbon DLS with Carbon materials (EPU 41, EPU 40, UMA 90) and Carbon’s software for quick design edits, Blue Danube Robotics produced elastic AIRSKIN pads, cable mountings and mounting brackets with superior surface finish, reliable 0.8–0.9 mm sensor walls (enabling ~0.5 N detection), and parts that clip together cleanly. Carbon’s solution cut design‑to‑part time from up to a week to one day, enabled in‑house rapid prototyping and scalable low‑volume production, and delivered measurable improvements in fit, durability, and development speed.

AIRSKIN

Andreas Baldinger

Chief Executive Officer