The CY1000 is the first product introduced by Q5D, a UK-based manufacturer of wire harness automation apparatus for additive manufacturing.

The 5-axis CNC robotic cell for additive manufacturing solves what the company says is a particularly difficult automation problem: how to automate the addition of electrical connections to increasingly complex products.

The CEO of Q5D, Steven Bennington, stated, “Currently, almost all wiring harnesses in this $200 billion-plus market are made by hand. With electrification, the internet of things, and net zero driving demand for cabling, automation is the only way to keep up.”

Q5D Electrical Function Integration

Traditional wiring harnesses are expensive, cumbersome, and space-hungry. In contrast, the CY1000 adds components, connections, and conductors to metal, ceramic, and polymer products and components automatically, economically, and securely. The company’s distinctive method is known as “Electrical Function Integration.” It eliminates the need for discrete, costly, and prone-to-fault wiring harnesses, reduces design constraints, increases reliability, and reduces costs. 

It can also secure and simplify supply chains by eliminating labor dependence. Wiring can be co-located with the final assembly thanks to the CY1000’s self-contained manufacturing cell, eradicating the costly transportation of heavy harnesses. Wire harnesses are frequently the final obstacle to complete automation for manufacturers of everything from automobiles to hand tools. Typically produced by hand, they are becoming increasingly complex, heavy, susceptible to wear and injury, and expensive to produce and maintain. Due to the labor-intensive nature of harness production, harnesses are frequently manufactured in countries with minimal labor costs, while final product assembly typically occurs thousands of miles away. This increases the cost, complexity, and risk associated with the supply chain.

The CY1000 features a robotic platform and gantry with a steel structure. It is designed for standalone use as well as simple integration into a process line, where it provides full-depth access for robotic loading. Each machine can add exposed or insulated wire and extrude a wide variety of polymers, including Nylon, PEEK, and Kydex, using a variety of specialized tools. Additionally, it can select and position electrical connectors and components. With these diverse capabilities, the CY1000 generates three-dimensional shapes, adds components, and wires them together with precision.

Flexibility is fundamental to the CY1000’s ability to boost productivity. The system can work with large components or parts (up to 1m in diameter), or multiple smaller parts can be formed by molding, stamping, or other conventional techniques before being loaded into the manufacturing cell, which locates the part and adds electrical functions as specified by the designer using a CAD/CAM based on Siemens NX, but with a custom motion controller, post-processor, simulator, and other tools.

The CY1000 has external dimensions of 2300mm by 2170mm by 2320mm, and its working area has a diameter of 1000mm and a height of 300mm. The X and Y axes operate at speeds of 1m/s, the Z axis at speeds of 0.5m/s, and the head and bed axes at speeds of up to 70 revolutions per minute. A touch screen and keyboard are used to operate the machine. In addition to control functions, the interface provides a status and performance summary of the manufacturing platform and displays productivity and quality data, if available.

The CY1000 is equipped with polymer and wiring end effectors, which are custom-made for each application. Copper wires up to 3 mm in diameter may be exposed or insulated. End effectors for conductive ink will be available later this year.

A case study in decreasing fuel consumption

Speaking to 3D Printing Industry, Q5D gave additional details about the Electrical Function Integration process. The CY1000 stands out from traditional wiring harnesses by fixing wires in place, which minimizes the chance of chaffing and environmental damage, ultimately reducing reliability issues related to vibration.

The CY1000 is also expected to have a significant environmental impact. By shortening the supply chain and eliminating the need for over-specifying cabling, the machine can lead to weight savings and reduced fuel consumption. A study in the aviation sector revealed that implementing the CY1000 could achieve a weight saving of over 10lbs (4.5kg) per aircraft seat, translating to an estimated fuel saving of 0.5 tons per year for a wide-bodied jet.

While the CY1000 is being launched today, Q5D has been working closely with leading aerospace and automotive companies in evaluating its potential. Due to the high degree of customization required for aircraft seating and interiors and the small quantities involved, their production is labor-intensive and costly. For instance, different aircraft require different seats, as do varying positions within the fuselage of a given aircraft. 

As seat adjustability, reservation indicators, infotainment systems, phone and computer chargers, and illumination become more advanced, wiring in and around seat components becomes more complicated. The wiring is installed in the numerous seat components and storage compartments.

In this trial of Electrical Function Integration, the additive manufacturing process utilized a standard blow-molded polymer core to incorporate stiffening and customization features, as well as the automated integration of wiring and terminations. Kydex is an approved material for aircraft interiors because it complies with pollution, fire, and toxicity regulations. Q5D has demonstrated the ability to 3D print Kydex features onto other Kydex surfaces.

The results demonstrated an increase in productivity and a weight reduction of 4.5kg per seat, and an increase in available space due to the replacement of distinct wiring harnesses and their attachments. The process readily adapts to product variants, and all necessary adjustments can be made in less than 15 minutes. 

The weight reduction increases the aircraft’s range and decreases its CO2 emissions. Alternately, more functions could be added to each seat without adding additional weight, thereby enhancing the passenger experience.

Q5D also has plans for future developments, such as conductive ink end effectors, and is working on heads for different materials and techniques, with announcements expected later this year.

As for the impact on the labor market, Q5D believes that the CY1000 will help alleviate supply chain issues across various industries without immediate job displacement. The machine is expected to facilitate the on-shoring of manufacturing in many economies, including the United States. This technology is poised to revolutionize the wiring harness industry, offering significant reliability improvements, cost savings, and environmental benefits.

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Featured image shows the CY1000 Additive Manufacturing Robot. Image via Q5D