Reducing Tooling Costs for Robot Housings

Cost-Effective Production with Low Tooling Costs

Before the robot could go into series production, the company faced a crucial challenge: the housing components not only had to be hygienic, scratch-resistant, and durable, but also needed to be produced economically—without compromising on quality.

„When we reached the point where the prototype worked perfectly, we wanted to turn it into a series product. The question was: How can we achieve cost-efficient series production in Germany?" – Matthias Krinke, Managing Director at pi4_robotics

In addition to keeping tooling costs low, the design also needed to remain flexible enough to allow for future adjustments to components like microphones or cameras. This flexibility was especially important, as developments in robotics and AI often lead to changes that require technical adaptations.

Durable and Scratch-Resistant Material for Everyday Use in Care Settings

This is where formary came into play. pi4 was looking for a partner that could offer comprehensive advice on all aspects of thermoforming and material selection. Special attention was paid to the adaptability of the components—both for future modifications and for minimizing tooling costs in series production.

„Our task was to develop a solution that met all the requirements." – Moritz Bittner, formary

The robot’s housing components had to be extremely resilient—especially in terms of scratch resistance and hygiene. In a care facility, where the robot constantly comes into contact with various surfaces and caregivers, it’s essential that the surface is both robust and easy to clean.

Choosing the right material was therefore critical. For the prototypes, formary sourced special materials in small quantities, including PMMA/ABS high-gloss sheets in RAL 9016 (Senoplast) and RAL 9003 as a secondary option.

Prototype Manufacturing with Wooden Substructures for Fast Implementation

As part of the collaboration, formary arranged a supplier site visit for pi4 as well as a virtual audit of the tool manufacturer—all efficiently handled in a single appointment.

For the initial sample production, a cost-effective solution with wooden substructures was used. Full aluminum was selected only for series production to ensure a durable and stable structure.

Thanks to the close collaboration, all 8 tools along with the initial samples were delivered within 6 to 7 weeks. The CAD data was optimized in several team meetings, with the formary Design Guide serving as a valuable reference for fine-tuning. The result: a perfectly matched, thermoforming-ready solution.