3D-Printed Gripper Heads for Delicate Low-Area Components

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Solution Overview

Problem

Conventional suction cups require a minimum surface area and threshold suction force, making them unsuitable for delicate components, and introduce secondary valves that increase cycle time and system weight, reducing performance.

Innovation Solution

A gripper head apparatus with interchangeable gripper heads and an air conveyor system that generates airflow to securely hold components with minimal surface area or fragility, allowing for efficient transport and release.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional suction cups are used to transport components, then components with sufficient surface area can be held securely, but components with minimal surface area or delicate structures cannot be transported without risk of damage

Engineering Contradiction:

Improvecomponent holding reliabilityVSAvoidcompatibility with delicate components

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent changes the fundamental parameter of suction generation from mechanical pressure application to aerodynamic lift. The air conveyor creates a controlled airflow field that generates lift forces on the component surface, replacing the traditional suction pressure mechanism. This parameter change enables handling of delicate components with minimal surface area that cannot withstand conventional suction forces.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs pneumatic principles through the air conveyor system that generates controlled airflow. Instead of using mechanical suction cups that apply direct pressure, the system uses a stream of air to create lift and hold components. This pneumatic approach allows for gentler, more adaptable handling of fragile components while maintaining reliable transport capability.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Ease of operation

If secondary valves are added to conventional suction cups for component ejection, then component release is enabled, but the cycle time of the transport unit increases

Engineering Contradiction:

Improvecomponent release capabilityVSAvoidtransport cycle time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent extracts and eliminates the secondary valve component from the system. Instead of adding a valve mechanism for ejection, the system uses the primary air conveyor to control both holding and release. By removing the secondary valve, the patent reduces mechanical complexity and eliminates the time required for valve actuation, thereby reducing the transport cycle time while maintaining full component release capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The air conveyor serves multiple functions: it generates the airflow field for holding components, controls the suction force, and enables component release by adjusting airflow parameters. This multi-functionality eliminates the need for separate ejection valves, reducing system complexity and cycle time while maintaining ease of operation for component release.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Force

If large suction rate is required for conventional suction cups, then component holding force is sufficient, but the weight and size of the end of arm tooling increases

Engineering Contradiction:

Improvesuction holding forceVSAvoidend of arm tooling weight

Core Design Contradiction:

ForceVSWeight of moving object

Solution Approach 1:

The patent replaces the mechanical suction cup system with an aerodynamic field-based system. Instead of using heavy mechanical components to generate suction force, the system uses an air conveyor to create a controlled airflow field that generates lift forces. This substitution reduces the weight and size of the end-of-arm tooling while maintaining sufficient holding force through aerodynamic principles rather than mechanical pressure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables secure transport of delicate components with minimal surface area without increasing system weight or cycle time, enhancing system performance by reducing the need for secondary valves and minimizing size and weight.

Implementation Method 1

an air conveyor positioned within the chamber. The air conveyor is configured to generate the air flow through an inlet and out through the exhaust

Methodology Applied

Scientific EffectAirflow generation:

Implementation Method 2

based on an air flow generated within the chamber and discharged through the exhaust... to locate and releasably hold a component

Methodology Applied

Scientific EffectVacuum suction: Suction

Data Source

PatentUS12491680B2Method for forming gripper heads used to transport components

Publication Date: 2025.12.09 THE GILLETTE CO

AI summary

A method is provided for forming one or more gripper heads to be used with a gripping apparatus. The method includes obtaining 3D data based on a geometry of a component. The method also includes forming one gripper head comprising 3D printing the gripper head based on the obtained 3D data. The forming step includes forming one or more openings in the gripper head and forming a nest of the gripper head to locate and releasably hold the component based on suction being applied through the one or more openings.