Manufacturing cell

The world’s first CAD/CAM manufacturing cell for automated production of wiring.

Our robotic manufacturing cells replace manual assembly processes by applying wires and connectors directly to the product, sub-assembly or component.

A range of deposition techniques can be deployed to add electrical functionality using interchangeable end effectors. These tools deliver:

Insulated wire deposition
Bare wire deposition
Wire termination to connector
Polymer deposition
Printed electronics (Future Release)
Pick and place of connectors and small components (Future Release)

CY10 specification

The CY1000 is a self-contained manufacturing cell:

Stand alone design requires only power and internet connection
Robust tubular steel frame for rigidity and durability
High speed linear motors to maximise speed and productivity
Steel and impact resistant polymer cladding for safety and environmental control
HEPA filtration of internal environment
Safety interlocked full width door for loading, can be configured for co-acting robot loading
Ergonomic operator station
Accommodates continuous supply from external material warehouse

Swipe tables

	Dimension
Length (mm)	2300
Depth (mm)	2200
Height (mm)	2300
Weight (Kg)	2000
Robot arm maximum travel speed (mm/s)	3000

Build capacity

Unlike traditional additive manufacturing systems, the CY1000 is designed to be a hybrid manufacturing system. Components or products that need electrical function can be loaded and have wires and features added to them. As a result the system will accept large parts.

The build volume describes the maximum size component that can have 5 axis manufacturing applied to it the whole volume. Larger parts can be accommodated, but some flexibility of operation is compromised.

	Dimension
Build volume diameter (mm)	1000
Build volume height (mm)	500
Maximum weight (Kg)	30

Built for production

The CY1000 is a production tool. Speed, accuracy, repeatability and the ability to work as a self-contained unit or in conjunction with other CY1000 machines and cooperative robots to create a production system.

Swipe tables

Axis	Axis stroke	Max speed	Max acceleration	Accuracy (ideal)	Repeatibility
X	1500 mm	1m/s	10m/s²	±5µm	±2µm
Y	1050 mm	1m/s	10m/s²	±5µm	±2µm
Z	750 mm	0.5m/s	8m/s²	±5µm	±2µm
B (head)	240° (-110° / 140°)	200rev/min	200rev/min²	±30 arc sec	±10 arc sec
C (bed)	360° Continuous Rotation CW/CCW	200rev/min	200rev/min²	±10 arc sec	±5 arc sec

Normal operating speed for rotational axis is 70 rev/min

B and C motion motors are hollow to permit continuous material delivery to end effectors from exterior stores.

Hollow B and C motor specification:

	B Axis	C Axis
Mass	< 3Kg	<12Kg
Diameter	120 mm	150mm
Total length	120 mm	150mm
Continuous torque	15Nm	100Nm
Hollow shaft	15mmØ	15mmØ
Positional accuracy	< 30 arc sec	< 10 arc sec
Repeatability	< 10 arc sec	< 5 arcsec

End Effectors

Insulated wire

Deposits insulated wire and terminates to Insulation Displacement Connector (IDC).

	Attribute
Wire types	Most twisted or solid conductor
Maximum wire diameter (mm)	3
Maximum deposition speed (mm/s)	300

Material supply from reel mounted on end effector (standard) or external warehouse (option).

300mm/s

Wire deposition speed

0.05mm

Repeatable accuracy

Bare wire

Deposits bare wire and terminates to Insulation Displacement Connector (IDC).

	Attribute
Wire types	Solid conductor in Cu or Al
Maximum wire diameter (mm)	3
Maximum deposition speed (mm/s)	200

Material supply from reel mounted on end effector (standard) or external warehouse (option).

200mm/s

Wire deposition speed

0.05mm

Repeatable accuracy

3D polymer featuring

Deposits polymer in complex 3D shapes. 5 Axis manufacturing provides flexibility in shape and eliminates most support structure needs compared to 3D printing. Used to:

add wire traps
over print wires to secure them
over print connectors and bare wires for insulation
create 3D features such as securing bosses to support variant flexibility based on a single substrate type.