ADVANCED MATERIALS & PROCESSES | SEPTEMBER 2025 19 Fig. 3 — (a) CAD file of one section of the toroidal tank. Blue highlights the actual part and the gray is the skirt. The part is (b) RoboFormed from 0.125-in. thick AA5052-H32, stress relieved, and then (c) trimmed. The panels are then (d) hand welded using a weld fixture and (e) released. (f) Multiple subassemblies (author for scale) are then welded together to form (g) the final toroidal tank. Fig. 4 — The current generation of the RoboCraftsman could form parts at Machina Labs headquarters in Los Angeles, get packed up into two ISO containers, shipped to a different location, and be deployed, ready to make parts within days of arrival on site. the desired specifications. After RoboForming, the part can optionally undergo heat treatment for stress relief and/ or to achieve the final temper. Next, the robot arms replace their forming end-effectors with machining spindles to trim the part, liberating the desired area from the skirt. To fabricate a full assembly, multiple trimmed parts can then be joined. Traditional joining methods such as welding and riveting are currently employed, and in situ robotic assembly capabilities within the RoboCraftsman are being actively explored. This includes on-frame joining oper- ations, where subcomponents are welded or fastened directly within the robotic cell, eliminating further material handling and streamlining the overall manufacturing flow. By integrating all operations from forming and scanning to trimming and joining within a single versatile manu- facturing cell, the RoboCraftsman is redefining what end-to-end sheet metal assemblies can look like in modern manufacturing environments. Figure 3 outlines an example process flow used to assemble a toroidal tank for NASA. ADAPTIVE PRODUCTION FOR MODERN SUPPLY CHAINS The past several years have revealed the fragility of traditional, centralized manufacturing models. Delays due to material shortages, transportation disruptions, and sudden demand spikes have highlighted the need for adaptable, location-agnostic production methods that can flex to meet changing conditions. Whether producing components for aircraft, vehicles, or energy systems, manufacturers now require solutions that can move, scale, and reconfigure in response to real-time needs. The RoboCraftsman platform was built with this flexibility in mind. Housed within two ISO-standard shipping containers, the system can be rapidly deployed anywhere with power and minimal site preparation. It allows manufacturers to move production closer to where parts are needed, whether for prototyping, producing spares, or full-rate production. This decentralized approach not only shortens lead times but also enhances resilience by reducing dependence on centralized tooling and long logistics chains (Fig. 4). The software-defined nature of the RoboCraftsman enables switching from one part geometry to another with minimal hardware changes. It usually just involves manipulating a new CAD model to generate toolpath instructions. This enables rapid changeovers between part families, supports high-mix workflows, and allows manufacturers
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