Case Study: FreeFORM Technologies achieves durable, lightweight, and 4x-lower-cost automotive end-of-arm tooling with ExOne Innovent+ binder-jet 3D printing

BinderJet 3D Printing Delivers Durable, Lightweight & A ordable Automotive End-of-Arm Tooling

FreeFORM Technologies was asked to produce a durable, lightweight end-of-arm tooling (EOAT) attachment for a high-volume robotic inspection process that required two tools to sit 90° to each other and handle varying part weights. Traditional prototypes in carbon‑reinforced plastic lacked durability and machined aluminum would have been too heavy, so FreeFORM turned to ExOne’s binder jet 3D printing (ExOne Innovent+) to pursue a generative-design metal solution.

Using the ExOne Innovent+ to print in 17-4PH stainless steel, FreeFORM produced a 4.5 x 2 x 2 in part weighing 95 g that met MPIF standard 35 (98% density, HRC 27) and was printed in under a day. The ExOne-enabled binder jet process cut pre-finishing cost to $150 versus $672 for DMLS (about one‑fourth the price), delivered ±2.5–3% initial accuracy (improvable to <1%), and reduced robot payload—improving durability and expected robot life while meeting the customer’s performance requirements.

FreeFORM Technologies

Chris Aiello

Vice President of Business Development