Bastian Solutions Shuttle System: Additive Manufacturing for Custom Materials Handling Robots
Case study showing how Bastian Solutions used additive manufacturing to build a customizable robot arm-and-shuttle system, cutting two years from development and saving $100,000 in production costs.
Bastian Solutions partnered with Fast Radius to develop the Shuttle System, an autonomous materials handling robot designed for variable warehouse environments. Nearly 50 percent of the bill-of-materials was produced using HP Multi Jet Fusion and Carbon DLS technologies, replacing metal components with lightweight polymer parts. The approach eliminated tooling, enabled rapid iteration of hundreds of prototypes, and delivered a multi-faceted adaptive gripper capable of handling diverse SKUs. The project reduced development time by two years and lowered production costs by $100,000.
Additive manufacturing replaced metal parts with HP PA 12 Glass Beads, reducing robot weight and energy consumption.
Tooling-free production allowed same-day design changes and parts delivery in days instead of weeks.
Carbon DLS enabled a proprietary Shark Fin adaptive gripper using EPU 40 for handling varied product shapes and weights.
Hundreds of prototypes were designed, printed, and tested in under 20 months.
Project timeline shortened by two years with $100,000 in direct production cost savings.
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