How Metal 3D Printing Empowers Humanoid Robotics — BLT Showcases Cutting-Edge Applications

Panda3dp.com Exclusive — October 2025
How is metal 3D printing reshaping the future of humanoid robotics? From lightweight structural components to micro-scale force sensors, Bright Laser Technologies (BLT) is demonstrating how additive manufacturing enables lighter, stronger, and more efficient next-generation robots.

From October 15–17, 2025, BLT was invited to exhibit at the 2025 Shanghai International Humanoid, Special, and Service Robot Expo, showcasing innovations across core structural assemblies, dexterous hand components, and transmission systems — a comprehensive display of the company’s latest breakthroughs in robotic manufacturing.

Lightweight Breakthroughs in Robotic Structural Design

BLT’s approach to integrated design and precision metal additive manufacturing has delivered remarkable advances in robotic component performance.

· Air-Cooled Heat Sink:
Incorporates multi-fin configurations optimized for various working conditions, allowing on-demand functional design while maintaining efficient heat dissipation.

· Planetary and Bevel Gears:
Through optimized topology and lattice integration, BLT achieved weight reductions of 66% and 65%, respectively, while maintaining high torque and durability.

· Screws and Pins:
Using hollow architectures and multi-scale internal lattice structures, BLT reduced weight by up to 85% and 70%, respectively, without compromising rigidity.

Together, these designs highlight BLT’s expertise in enhancing robotic motion efficiency and payload capacity through advanced structural engineering.

The “Lattice Cube”: A Symbol of Structural Innovation

A highlight of BLT’s exhibit was its Lattice “Magic Cube”, which integrates multi-scale lattice structures into a unified form — each tuned to mimic different biomechanical properties.

This experimental piece reflects BLT’s ongoing exploration of bionic structural design, aimed at achieving the optimal balance between strength, flexibility, and weight in humanoid robot architectures.

Precision Force Control: Joint Development with Haptron

In the realm of precision force sensing, BLT has collaborated closely with Haptron Technology to co-develop a new generation of metal 3D-printed multi-dimensional force sensors — pushing the limits of robotic tactile perception.

Photon Finger — The World’s Smallest Six-Dimensional Force Sensor

Utilizing integrated metal additive manufacturing, each batch can be fabricated in just 20 minutes, with 15–30 units per build.

· Overload tolerance: improved by 50–250%

· Compact form factor: delivers superior mechanical resilience and signal fidelity

Photon Finger Max — Second-Generation Multi-Dimensional Sensor

With a diameter of only 9.5 mm and a load range increased 23× to 700 N, the sensor uses high-strength alloys and structural optimization to enable rapid design iteration and long-term reliability.

Tactile Perception for Dexterous Hands

BLT and Haptron successfully embedded a multi-dimensional sensor (diameter: 8.5 mm) into a robotic finger joint, achieving micro-force detection precision of 0.05 N — granting humanoid hands near-human tactile sensitivity.

Toward Smarter, Lighter, and More Responsive Robots

Through its collaboration with partners like Haptron, BLT continues to advance the integration of metal additive manufacturing in robotics, combining structural innovation with functional intelligence.

From lightweight transmission systems to ultra-compact force sensors, BLT is enabling humanoid robots to move more efficiently, sense more delicately, and perform more like humans — marking a decisive step toward the next generation of intelligent robotic design.