At the recent webinar “Breaking the Lightweight Barrier: Industrial-Grade FFF 3D Printing Paves the Way for Mass Production of Humanoid Robots”, INTAMSYS shared insights into how industrial-grade FFF 3D printing is driving this transformation.
The Humanoid Robot Industry on the Verge of a Breakthrough
According to the Humanoid Robot Industry White Paper, China’s commercial shipments of humanoid robots reached approximately 2,000 units in 2024, with 182 financing deals totaling USD 2 billion. By 2025, production is expected to exceed 10,000 units, with the domestic market size approaching USD 1.4 billion, while the global market could reach USD 100 billion by 2035.
Driven by large-scale AI models and rapid advances in robotics, humanoid robots are evolving toward greater intelligence, miniaturization, cost efficiency, and general-purpose adaptability. Applications are expanding from manufacturing to medical services, education, and even household companionship. At a policy level, the Chinese government has expressed clear support, recognizing humanoid robots as a strategic industry comparable to the EV supply chain.
Why FFF 3D Printing Is the Key to Solving Lightweighting and Iteration Challenges
Humanoid robot manufacturers face three major challenges: reducing weight without compromising strength, validating new designs quickly, and achieving cost-effective small-batch production ahead of full-scale manufacturing. FFF 3D printing provides a highly effective solution.
Unlike metal machining or injection molding, which involve high upfront tooling costs and long iteration cycles, FFF can transform 3D design data directly into physical parts, eliminating the need for molds and dramatically shortening development time. Its ability to realize complex topologically optimized structures makes it ideal for lightweighting, while its broad material compatibility—from engineering plastics to high-performance composites—gives designers more flexibility to balance weight, strength, and durability.
The precision and consistency of industrial-grade FFF also mean it is no longer limited to prototyping. With proper process optimization, functional and structural components can be directly applied to final assembly.
From Head to Toe: FFF’s Expanding Role in Humanoid Robots
FFF 3D printing is already being used across nearly all critical components of humanoid robots.
Head modules, such as camera housings and sensor brackets, are being printed for quick customization and functional verification. Lightweight skeletal structures, joint covers, and limb shells—spanning shoulders, elbows, knees, and feet—benefit from complex lattice or topology-optimized designs that achieve both strength and weight reduction.
High-performance materials are enabling the production of functional components such as gears, linkages, and joint housings, meeting demanding mechanical requirements. Control unit housings, wire protection covers, and even AGV chassis boxes are increasingly produced via FFF for flexible, small-batch customization.
For exterior aesthetic parts, which often require frequent design updates, FFF offers unmatched speed—allowing designers to move from digital models to finished parts in just a few days.
Why FFF Outperforms Other 3D Printing Processes for Robotics
Compared to SLS, SLA, and silicone molding, FFF stands out as the most practical option for robot component manufacturing. SLS is prone to warping and deformation in large, thin-walled parts due to uneven heat dissipation, while SLA resins are brittle and lack the thermal stability required for functional components. Silicone molding, though flexible, involves high tooling costs and limited mold lifespans, making it unsuitable for rapid iteration.
FFF, by contrast, supports a wide range of materials—including ABS, PC, PA, PEEK, and PEI—and ensures dimensional stability and mechanical consistency through advanced heated chamber technology and servo-controlled systems. This makes it exceptionally well-suited to the lightweighting, rapid iteration, and flexible production requirements of humanoid robots.
INTAMSYS FFF Solutions Accelerating Robot Manufacturing
INTAMSYS FUNMAT PRO 610HT exemplifies the capabilities of industrial-grade FFF. With a build volume of 600x500x500mm, a 500℃ nozzle, and a 300℃ heated chamber, it supports high-performance materials such as PEEK, PEI, and PPSU while maintaining mechanical consistency critical for end-use assembly.
For smaller-scale production, the FUNMAT PRO 310 NEO offer cost-effective solution. Its independent dual-nozzle IDEX design enables up to 1 kg of daily output, making it ideal for small-batch production.
To date, INTAMSYS has collaborated with over 20 humanoid robot companies, delivering solutions for lightweight structural components, joint housings, and customized exterior parts—helping bridge the gap between R&D and mass production.
Industrial-grade FFF 3D printing is emerging as a key enabler of humanoid robot commercialization. By combining lightweighting, high-performance materials, and rapid production, it is accelerating the journey from concept to large-scale deployment.
Watch the webinar replay or talk to our sales team to explore how INTAMSYS can support your humanoid robot manufacturing projects.
Learn more about the humanoid robot application.
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