Case Study: DMG MORI achieves 62% lighter robotic end‑effector, 60% fewer components and 16x handling precision with nTopology

DMG MORI Redesigns Robotic End-Effector using Topology Optimization & Reusable Workflows

DMG MORI’s ADDITIVE INTELLIGENCE team needed to redesign the Robo2Go robotic end-effector head to maximize stiffness-to-weight, improve handling precision, and cut manufacturing costs — all while keeping the part’s external form and integrating pneumatic and electrical components. To achieve this, DMG MORI used nTopology’s generative design and topology-optimization software as the core tool for the project.

Using nTopology, engineers applied topology optimization to vary shell thickness, filled the shell with a conformal lattice for stiffness and support, and built a reusable, automated workflow based on color-coded surfaces. The result was a part that is 62% lighter, uses 60% fewer components, delivers 16x higher handling precision, and reduces pneumatic sealing points by 45%, manufactured in AlSi10Mg on a LASERTEC 30 Dual SLM.

DMG MORI

Martin Blanke

Additive Manufacturing Project Engineer