Robots may already be common throughout the manufacturing industry, but the robotics market’s growth is far from over. Now that automation itself can no longer differentiate a facility from its competitors, attention turns to making these machines safer, faster, more accurate and versatile. End-of-arm tooling (EOAT) design is driving much of this change.

As the point of contact between robots and what they work with, EOAT’s impact on productivity and production quality is substantial. To reach your full potential in these areas, you must capitalize on the latest EOAT innovations. Here are eight of the most significant.

1. Adaptive Grippers

Robotic grippers are among the most popular types of end-of-arm tooling design and, as such, are experiencing some of the most advancement. Adaptivity is driving many of these improvements.

New EOAT designs use sensors and artificial intelligence (AI) to detect and respond to changing conditions. That lets robotic hands loosen or tighten their grip to hold objects firmly without damaging them. It also ensures the same EOAT can handle a wider variety of materials and shapes.

Adapting to changing conditions also ensures robots can operate as energy-efficiently as possible. Some adaptive grippers can reduce their grasping force to just 20% of their maximum, leading to substantial energy savings and less wear and tear on the EOAT.

2. No-Code EOAT Software

Other EOAT tooling innovations focus on the human side of robot operations. Switching a machine’s tooling often requires software changes, not just replacing physical components. Implementing a brand-new system involves even more software-related optimization. However, 54% of all organizations are experiencing tech skills shortages, so coding requirements are an increasingly difficult obstacle.

Low-code and no-code EOAT software is becoming more common in response to this skills gap. Newer EOAT packages feature plug-and-play functionality, making installing or adjusting robotic tools to your specific environment easier.

Automated systems almost always require adjustment to reach their full potential. No-code controls lower the barrier to that optimization, so using these software tools can put manufacturers at a significant advantage before they become the industry standard.

3. Modular Tooling

End-of-arm tooling design is also moving toward modularity. As no-code software enables plug-and-play functionality on the control side, modular tooling does the same to a robot’s hardware.

Modular EOAT platforms let a single robotic arm fill multiple roles with minimal changeover time. Alternatively, manufacturers can test slight variations on the same kind of tooling to optimize one process to their unique needs. Modularity can also reduce hardware expenses by letting companies order end-of-arm tools in larger volumes to fit one or two robots instead of purchasing multiple bots.

Some modular EOAT platforms have automated tool changeover functionality. These features lead to less downtime, as they can work faster than manual alternatives and allow technicians to focus on other tasks.

4. Nature-Inspired Grips

Another growing movement in EOAT is basing grip designs on nature. Mimicking the human hand, octopus tentacles, and other natural gripping mechanisms enables more versatile and less energy-intensive tooling designs.

Gecko-inspired robotic grippers have seen particular interest as of late. Geckos can stick to most surfaces thanks to microscopic hairs on their feet. Robot hands can imitate this effect through tiny polymer structures, letting them pick up various materials and shapes without increasing pressure or using chemical adhesives.

These nature-inspired grippers eliminate contamination risks from strong adhesives while providing more versatility than magnetic or vacuum gripping tools. They also require less mechanical force to create sufficient gripping pressure, reducing energy consumption and related costs.

5. Smaller Form Factors

End-of-arm tooling is getting smaller. While larger tools may be able to work with bigger components, bulky machinery isn’t ideal in most cases. Recent breakthroughs allow EOAT to perform the same work in a more compact package.

Some tactile grips require minimal or even no electricity to operate, reducing the need for wires. Similarly, tools requiring less mechanical force don’t need as much surrounding machinery to work effectively. These upgrades let manufacturers reduce their robots’ size and weight, lowering energy consumption and enabling more delicate operations.

Some cutting-edge solutions are as small as 2 square centimeters — small enough to fit at the end of a gripper without requiring additional allowances.

6. Machine Vision Integration

Some end-of-arm tooling design innovations address EOAT’s complementary systems, not the tooling itself. One of the most promising developments is the integration of machine vision technology.

Machine vision is the branch of AI that deals with processing visual input. Connecting these systems to EOAT enables robots to adjust their grip and movement on visual factors, not just tactile sensors. This broader variety of sensory input lets them operate more accurately.

Today’s machine vision systems can achieve higher visual accuracy than human eyes and make judgments based on this information in less time. That allows them to recognize if an object is misaligned or if they must move something before working on it, preventing costly errors while maintaining high productivity.

7. Safety-Focused Cobots

As EOAT advances, robots can accomplish more with less human input. Consequently, more are starting to work alongside humans as cobots instead of relying on operators’ controls.

These cobot working arrangements are more flexible and efficient than entirely manual or automated workflows. However, they also introduce safety concerns. Collisions with equipment or objects are the second leading cause of injury in manufacturing, so there’s a growing movement for safety-focused EOAT systems.

These solutions often involve motion sensors or machine vision to recognize humans and predict their movements. That way, they can stop or change what they’re doing to avoid collisions. Smaller, lighter tools also improve safety, resulting in less violent movement and fewer physical risks.

8. 3D-Printed Components

Like other manufacturing processes, end-of-arm tooling design is also embracing 3D printing. 3D printing end-of-arm tools can make these components more advantageous than previously possible.

The most obvious benefit of 3D-printed tools is that they’re affordable. 3D printing is faster, more energy-efficient and less wasteful than conventional machining, making its products more cost-effective. That speed and affordability also lower the barrier to entry for bespoke EOAT components.

3D printing filaments are also generally lighter than metals or conventional plastic parts. As a result, this practice enables smaller, lighter EOAT for better safety, efficiency and energy consumption.

End-of-Arm Tooling Design Is Rapidly Evolving

These eight innovations showcase how quickly end-of-arm tooling design is advancing. Before long, these practices will be standard throughout the industry. Capitalizing on them now is key to remaining relevant in a fast-evolving sector.