Robotic production of large-scale components

We talked to Matthias Leschok, co-founder of SAEKI.

Why is it so difficult to manufacture formwork for a large concrete part in a building or a mould for the hull of a space shuttle?

There are several aspects to this problem. First, the manual labour required to fabricate those elements is high, making it expensive and time-consuming. Second, there is a labour shortage of skilled craftsmen qualified to fabricate high-precision and/or complex shape elements.

Therefore, SAEKI provides a one-stop-shop digital manufacturing solution for the small-batch production of large-sized parts. Our solution essentially provides a micro-factory with a new way of manufacturing complex elements at competitive prices with increased speed.

The tool-head we developed is about 1.5m tall and quite powerful, specially made for large-scale components. Furthermore, our clients may use our patented printing technology to produce lightweight elements at an increased speed.

Our robot can produce full-circle components, from 3D printing to milling and sanding. SAEKI combines robotics, 3D printing, milling, post-processing, and 3D scanning for large-scale components. 

How does the technology work?

The technology enables switching back and forth between the different tools when working on a product, which is much more efficient and means the product doesn’t have to be moved. Depending on the component, we can produce large elements five times faster than other manufacturers.

Having a patent for a novel 3D printing technology, we can print objects such as formwork or interior elements up to 10 times faster with less material.

Our process starts with additive manufacturing in large dimensions. Then we subtract material with the milling tool to carve and form the parts in the correct shape. We also intend to integrate post-processing solutions, including a wide range of coatings, spraying, sanding, or inserting components into a print – all during manufacturing. In the future, we will integrate quality control inspections, to provide an all-in-one manufacturing solution.

What sets you apart compared to similar solutions?

We can offer the complete hardware and software automation package, consisting of the tools and material required for RDM, control, and design software.

A clear differentiating factor lies in enabling circular production: any waste products generated can be recycled. Concrete formwork, for example, can be reused, rather than discarded.

Furthermore, we will provide decentralised production hubs for large-scale components, fabricated close to where they are needed. Currently, we are setting up our first Hub of micro-factories.

What is planned in the near future and what is your vision?

At the moment, we are looking for more projects and collaborations within the industry to offer our solution. We just closed our pre-seed round and are looking for more team members in all fields of engineering.

Ten years from now, we envision lights-out factories filled with SAEKI micro-factories. They will be autonomously producing complex, material and weight-saving formwork for the construction industry, fixtures, and tooling for super-sonic jets, or composite moulds for the next generation of Formula 1 cars.