In production · seat cell
SeatStudio
Turns the shop's CAM program into a KUKA program: load, place on the table, check, send.
Autonomous manufacturing
Upload a model.
Get the part.
Old 3D printers took hours of setup. With a Bambu you upload the file, press print and it works. We are building that for manufacturing: you upload a 3D model, the robot measures itself, prints the part if it needs to and mills it to size. Nobody programs the robot.
01 · The problem
A new part costs most before the first cut.
Prototypes, moulds, seat foams, fixtures and the first parts of every series all need a program, a set-up and test runs first.
02 · Where the money goes
The machine is not the expensive part.
The people around it are: CAM and robot programming, set-up, test runs and hand work, paid again for every new part.
03 · What we do
We take those steps out.
One at a time, on standard industrial robots. In our seat cell the robot programmer is already gone.
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In production since September 2026
Our robot cell mills customer parts.
At ACCENTFORM in Nienstädt, a KUKA KR 210 on a linear rail mills seat foams for customer orders. The shop's CAM program goes into our software, a checked KUKA program comes out, and the robot runs it. There is no robot programmer in between.
Runningcustomer seat production on the cell, since September 2026
0robot programs written or edited by hand
40,010moves in one seat program, each checked before the robot runs it
How it works · SeatStudio
The operator presses send.
The software does the rest.
SeatStudio is the cell's app, written by us. The operator loads the job and places it on the table. Everything a robot programmer used to do happens in the five steps below.
- 01
Load
The part's 5-axis CAM program, as the shop already makes it for its CNC machines.
- 02
Place
The part goes on the table grid, corner on the locator, turned to suit the robot.
- 03
Orient
For every move, a tool angle the robot can reach, smooth from one move to the next.
- 04
Check
Reach, joint limits and collisions of robot, spindle, holder, part and table.
- 05
Run
The KUKA program goes to the controller and the robot cuts. Nobody edits a line.
Next in the cellTool change and tool measuring by the robot itself, and a 3D scan of the finished part. Then a part goes from upload to finished without anyone at the cell.
Built in-house · the cell's vacuum table
We build the cell ourselves.
The table every part is held on: two ABS plates from our own CAD, milled on the shop's 5-axis CNC, threads cut by hand, screwed together and set on the cell's grid.
- Top plate · ABS 19 mm · 23.2 mm squares, 6.8 mm grooves
- 21 × M6×30 screws · 16 at the edge, 5 inside
- Bottom plate · ABS 19 mm · seal groove 5 × 6 mm
- 876.5 × 936.5 mm · 9 vacuum ports Ø33.6
Top plate · 876.5 × 936.5 mmABS, 19 mm. 23.2 mm squares, 6.8 mm grooves 7 mm deep. 9 vacuum ports, Ø33.6
21 × M6×3016 at the edge, 5 in the middle of a square. Threads cut by hand, 16 mm deep
Bottom plateABS, 19 mm. Seal groove 5 × 6 mm, 25 mm in from the edge
Built in-house · holders and frames
Every holder from our own CAD.
The holders for measuring the tools are designed here, printed and keyed into the table grid. The laser frame stands on a welded steel stand.
Same software · 5-axis CNC
Wood parts and fixtures from flat sheets.
On the shop's 5-axis gantry, our software nests the boards, writes a program for every sheet, checks it and posts it for the machine. Fixtures, patterns and prototype parts come off the sheet ready to put together.
38boards, slotted together into two fixtures
7sheets of 19 mm birch plywood
5-axisKIMLA BFN 2141 gantry
Render of a fixture job on the KIMLA BFN 2141.
In the robot cell · in testing
The robot measures its own tools.
No more teaching the tool point by eye. Below, the real run: a camera watches the D60 cutter while the robot turns it through 50 poses, and the new tool point goes onto the controller. It has run with it since 13 Oct.
Camera footage of the cell, sped up. Three ways to measure, each built from catalogue parts and printed holders keyed into the table grid:
Laser cross
The tool passes two crossed beams. Where they break gives its axis, and the crossing gives its point.
Camera cross
Two cameras at 90° watch the tip against lit panels while the robot turns it. Nothing is touched.
Cone ring
A ball cutter seats in a printed cone and stays seated as the robot tilts it: the proof for the ball centre.
Renders from the cell's CAD model.
Second cell · in development
Gelcoat spraying, computed from the mould.
A KUKA KR 210 R3100 sprays gelcoat into moulds. The spray paths come from the mould's CAD, and the coat thickness is simulated on the GPU before the robot moves.
Our software
The tools we built,
and where they run.
All of it written by us. Some of it runs on customer jobs today, some is being tested in the cell, and the rest is on its way to the same cells.
In production · seat cell
Robot check
Every move tested for reach, joint limits and collisions of robot, spindle, holder, part and table before the controller sees it.
In use · 5-axis CNC
Sheet nesting
Nests the boards of a fixture on the sheets, writes and checks one program per sheet and posts it for the gantry.
In testing · robot cell
Tool measuring
A camera watches the cutter while the robot turns it. The measured tool point has been on the controller since 13 Oct.
Built · robot cell
Cell hardware
Vacuum table, locators, camera and laser holders: designed in our CAD, milled and printed in the shop.
In development · spray cell
Spray paths
Gelcoat paths from the mould's CAD, with the coat thickness simulated on the GPU before the robot moves.
In development · simulation
Two robots, one part
Splits one program between two robots and holds one back whenever the arms would come within 100 mm.
In development · browser
CAD, CAM and slicer
Design, toolpaths and print layers in one app in the browser, so a part goes from model to machine in one place.
In development · browser
Robot and FEA
Robot paths with the controller's own trace, and finite elements on the GPU checked against CalculiX.
Implicit CAM · in development
Toolpaths straight from the SDF.
Our own CAM on implicit geometry. It works on the part as a signed distance field, not a mesh, and computes roughing and finishing paths with the whole tool, holder included, checking the holder against the part.
Why us
Built inside a shop that makes these parts.
Our cells run in the hall of ACCENTFORM, a German shop that has made fibreglass, carbon and foam parts since 1998: theme-park figures, building facades, moulds and vehicle parts, one-offs and small series.
Every hard case reaches the cells first, so the system is built on real orders, not demos.
Film · 41 s
Cut, print, spray, calibrate, build, scale.
Contact
Need parts, a prototype
or a series? Talk to us.
Moulds, foams, composites, fixtures, figures and series parts. Or a cell like this in your own shop.