Case Study: Ghost Robotics achieves lightweight, durable, injection‑mold‑quality robot parts with Stratasys Origin One

How Ghost Robotics™ produces four-legged autonomous unmanned robots with the Stratasys Origin One 3D printer

Ghost Robotics makes size‑scalable, four‑legged Spirit™ Series robots and faced a need to produce lightweight, durable, cosmetically finished parts while staying agile for customer-driven design iterations. Traditional injection molding and CNC machining were too costly and slow, and other 3D printing options yielded anisotropic, weak parts with poor surface quality. Stratasys’ Origin One was identified as the suitable solution.

Using the Stratasys Origin One and materials from its ecosystem (Henkel LOCTITE 3172 and LOCTITE 3843), Ghost Robotics 3D printed nine parts per robot—including legs, soft toes and side panels—without redesigning CNC parts, enabling fast time‑to‑part and easy iteration. The switch eliminated tooling, cut costs by about 80%, delivered injection‑mold‑like surface finish via P3 technology, increased throughput and accelerated time to market while keeping parts rugged and ready for customer shipment.

Ghost Robotics

Gavin Kenneally

Mechanical Engineer