SYMPLEXITY · Project

Robots That Polish Complex Metal Parts Alongside Human Workers

manufacturingPilotedTRL 7

Polishing curved metal parts — think turbine blades, hip implants, or car body molds — is still done almost entirely by hand because robots can't handle the tricky shapes. SYMPLEXITY built systems where a robot does about 80% of the polishing work while a human handles the remaining 20% that requires finesse. They created three working demonstration cells using different polishing methods (abrasive, laser, and fluid jet) and tested them at real factory sites. The whole setup includes smart sensors that can "see" the surface quality in real time, so the robot knows when it's done.

By the numbers

90%

Current manual work in polishing that can be automated

80%

Robotic work share after implementation (under human control)

20%

Remaining manual work after implementation

Demonstrator cells built and tested at end-user sites

EUR 6,660,525

EU contribution to the project

Partners in the consortium

Countries represented

TRL 7

Target technology readiness level achieved

The business problem

What needed solving

Manual polishing of complex metal parts is one of the last manufacturing bottlenecks that resists automation. In sectors like aerospace, automotive, medical devices, and toolmaking, skilled workers spend hours hand-finishing curved surfaces because standard robots cannot handle the complexity. This drives up labor costs, creates quality inconsistencies, and makes it harder to compete globally.

The solution

What was built

Three demonstrator human-robot collaboration cells — one each for abrasive finishing, laser polishing, and fluid jet polishing — complete with cognitive robot control, safe human-robot interaction, autonomous surface sensing, and easy-to-use planning interfaces. All three were tested in operational environments at end-user factories.

Audience

Who needs this

Tool and die makers spending heavily on manual polishing laborAerospace component manufacturers needing consistent surface finishing on turbine bladesMedical implant producers requiring precise biocompatible surface qualityAutomotive OEMs and tier-1 suppliers finishing complex body or engine partsContract polishing and surface treatment service providers

Business applications

Who can put this to work

Tool and Die Making

mid-size

Target: Manufacturers of injection molds, stamping dies, and precision tooling

If you are a toolmaker spending most of your polishing budget on manual labor — this project developed human-robot collaboration cells that can convert over 90% of manual polishing work into 80% robotic work under human control and 20% manual finishing. The system includes sensors that objectively measure surface quality during the process, reducing rework cycles. Three demonstrator machines were built and tested in operational environments at end-user factories.

Aerospace Manufacturing

enterprise

Target: Producers of turbine blades, engine components, and structural parts

If you are an aerospace manufacturer struggling with consistent surface finishing on complex-shaped metallic components — this project built cognitive robot systems with safe human-robot collaboration specifically for aeronautical applications. The technology was validated at TRL 7 in operational environments with 3 end-user companies. Integrated autonomous sensing identifies surface properties in real time, helping meet the strict quality standards aerospace demands.

Medical Device Manufacturing

any

Target: Companies producing orthopedic implants, surgical instruments, and prosthetics

If you are a medical device maker where surface finish quality directly affects biocompatibility and patient outcomes — this project developed collaborative finishing solutions including laser polishing and fluid jet polishing for complex shapes. The system uses easy-to-use interfaces for planning and re-planning shared finishing tasks between robot and worker. With 19 partners across 8 countries and 6 SMEs in the consortium, the technology was designed for real industrial adoption.

Frequently asked

Quick answers

What would it cost to implement this kind of human-robot polishing cell?

The project itself received EUR 6,660,525 in EU funding across 19 partners to develop three demonstrator cells. Actual per-unit costs for a production cell are not disclosed in the project data. Contact the consortium for pricing on technology transfer or licensing.

Can this scale to full production lines, not just demo cells?

The project built 3 demonstrator cells tested in operational environments at 3 end-user sites, reaching TRL 7. The objective explicitly states bringing results to a level that supports European industry in global competition. Scaling from demonstrator to production line would require further engineering, but the operational testing is a strong foundation.

Who owns the IP and can I license this technology?

The consortium of 19 partners across 8 countries developed this technology, coordinated by Fraunhofer (Germany). IP ownership typically follows the EU grant agreement, meaning each partner owns their contribution. Licensing inquiries should be directed to Fraunhofer or the specific partner whose technology component you need.

Which polishing methods does the system support?

Three distinct process technologies were developed and demonstrated: abrasive finishing, laser polishing, and fluid jet polishing. Each has its own demonstrator cell with integrated sensing and human-robot collaboration interfaces. The choice depends on your material, geometry, and surface quality requirements.

How much manual labor does this actually replace?

Based on the project objective, case studies show that for many applications, today's over 90% manual polishing work can be converted into 80% robotic work under human control and 20% manual work. The human remains in the loop for complex decisions and fine adjustments, but the physical burden drops dramatically.

Is this safe for workers on the shop floor?

Safe human-robot collaboration was a core objective. The project built on SAPHARI (Safe and Autonomous Physical Human-Aware Robot Interaction), a prior EU project specifically focused on safety. The cognitive robot systems were designed to enable safe collaboration during surface finishing operations in industrial settings.

How long before this could be deployed in my factory?

The project ended in December 2018 with three demonstrator machines at TRL 7. Based on available project data, the demonstrators were ready for transfer to RTDs (research and technology development organizations). Moving to commercial deployment would require adaptation to your specific use case and production environment.

Consortium

Who built it

This is a heavyweight consortium with strong industrial DNA: 14 out of 19 partners are from industry (74%), including 6 SMEs, backed by 4 universities and Fraunhofer as coordinator — one of Europe's top applied research organizations. The 8-country spread (DE, EL, FR, IT, NL, PL, SE, UK) covers major European manufacturing hubs. The project builds directly on three prior EU projects (COMET, SAPHARI, poliMATIC), meaning the team had years of prior collaboration before SYMPLEXITY. For a business buyer, this means the technology was developed by people who understand factory floors, not just labs.

AUTODESK LIMITEDparticipant · UK
AUTODESKthirdparty · FR
DEBBACHE-LAGIOS EEparticipant · EL
HOCHSCHULE AALEN - TECHNIK UND WIRTSCHAFTparticipant · DE
HOGSKOLAN I HALMSTADparticipant · SE
SIR SPAparticipant · IT
AUTODESK BVthirdparty · NL
UNIVERSITA DEGLI STUDI DI MODENA E REGGIO EMILIAparticipant · IT
UNIVERSITA DEGLI STUDI DI ROMA LA SAPIENZAparticipant · IT
DELCAM LTDparticipant · UK

How to reach the team

Fraunhofer Gesellschaft (Germany) coordinated the project. Reach out to their manufacturing technology division for licensing and technology transfer inquiries.

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Next steps

Talk to the team behind this work.

Want to connect with the SYMPLEXITY team for technology licensing or a pilot assessment? SciTransfer can arrange an introduction and help evaluate fit for your production line.

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