Abstract:

The increasing adoption of Industry 5.0 technologies requires the development of lightweight, efficient, and human-centered robotic systems capable of operating safely in collaborative industrial environments. This paper presents ongoing research focused on the virtual design and validation of a six-degree-of-freedom robotic manipulator manufactured through Fused Deposition Modeling (FDM), intended for future implementation within a Digital Twin framework.

The proposed research investigates the influence of different thermoplastic materials (PLA, ABS, PETG, and Nylon) on the physical properties of the robotic arm while maintaining an identical CAD geometry. Using Autodesk Fusion 360, the study evaluates essential mass properties, including total mass, center of gravity, and principal moments of inertia, which directly affect the dynamic performance, actuator requirements, and energy efficiency of the manipulator. In addition, a multi-criteria material selection methodology is applied to identify the most appropriate materials for both structural components and machine elements according to their functional requirements.

The main objective of the research is to establish a reliable virtual validation workflow that supports material selection during the early design stages, reduces the need for iterative physical prototyping, and provides accurate physical parameters for future Digital Twin implementation. The study also includes the additive manufacturing and preliminary experimental validation of the robotic gripper, confirming the feasibility of the proposed design methodology.

The proposed approach contributes to the development of lightweight robotic systems for collaborative manufacturing by integrating CAD-based engineering analysis, additive manufacturing, and systematic material selection, while establishing the digital foundation required for future Human–Machine Interaction and Digital Twin applications.