How Apollon3D Automates the Additive Manufacturing Process – Interview with Lucas Apolinario

Apollon3D, based in the Netherlands, develops automated solutions for industrial 3D printing. The company operates its own production facility, offering additive manufacturing as a service while also providing automation systems to other 3D printing businesses. Its goal is to make production more consistent, scalable, and less dependent on manual labor.

The workflow starts when customers upload a design file. An automated validation system checks the file for printability and gives instant feedback on geometry or material issues. Once approved, the job is automatically scheduled, nested, and sent to production. Robotic post-processing and AI-based inspection ensure uniform quality: printed parts are scanned with high-resolution cameras, and any deviations from the digital model are detected in real time.

Material handling is part of the same automated setup. Filaments are stored in climate-controlled boxes that monitor temperature, humidity, and stock levels. Collaborative robots load the correct material into the printers, and every step of the process is logged and linked to project management software for full traceability.

By combining its in-house production capacity with automation technology, Apollon3D focuses on small-series manufacturing and research environments where consistent quality and reliable workflows are essential.

Interview with Lucas Apolinario

In the following interview with 3Druck.com, founder Lucas Apolinario shares how automation and AI are redefining Apollon3D’s approach to additive manufacturing and what this means for the future of industrial 3D printing.

Apollon3D highlights automation and AI as key parts of its approach. In practical terms, how do these technologies change the way you design and deliver 3D printing solutions compared to traditional additive manufacturing workflows?

Apollon3D’s approach to automation and AI transforms 3D printing by focusing on post-production quality assurance. While traditional workflows rely on a human operator for manual inspection—a process that is both time-consuming and prone to error—our system leverages AI to automate this critical step. Once a part is printed, it is sent to an automated inspection station where it is scanned using high-resolution cameras. The AI then compares this scan data to the original digital design, instantly identifying dimensional inaccuracies and surface flaws. This ensures a consistent level of quality for every single part, which is essential for scaling to larger production volumes and guaranteeing a reliable final product.

A core challenge in additive manufacturing is scaling up efficiently. How does Apollon3D’s automated production process help customers transition from one-off prototypes to consistent, larger-volume manufacturing?

Apollon3D’s automated production process helps customers transition from prototypes to larger-volume manufacturing by creating a scalable and repeatable digital workflow. This begins on our website, where our automated validation system checks the part file for printability and potential issues, providing immediate feedback. Once the design is validated, the automated system takes over, handling everything from job scheduling and part nesting to robotic post-processing. This removes the reliance on manual labor, which is a significant bottleneck in traditional additive manufacturing. By ensuring every print job is executed with consistent parameters and minimal human interaction, the automated process maintains high quality and efficiency, making it possible to produce hundreds or thousands of parts with the same reliability as a single prototype. This approach transforms 3D printing from a prototyping tool into a viable, large-scale production method.

Automation also plays a role in material handling and process control. How do you ensure that material selection, preparation, and validation are seamlessly integrated into your automated workflow?

The process starts with automated material handling, where materials are stored in specialized dryer boxes. These boxes maintain optimal temperature and humidity, keeping the materials in perfect condition, free of contamination, while also tracking material quantity. When an order is received, a cobot is triggered to pick and load the correct material directly into the printer. This ensures the right amount of material is used for each job. During the printing process, a centralized control system monitors key parameters, logging all data from every print run. This complete automation guarantees consistency and provides full traceability, as every piece of data is stored and linked to project management software, creating a comprehensive digital record for each part.

Looking at the future of additive manufacturing, what trends or innovations do you think will have the biggest impact on how the industry develops in the next few years?

The biggest innovation set to reshape our industry is the convergence of robotics and AI to create “lights-out” factories. These completely autonomous facilities can operate 24/7 with minimal human supervision, representing a new era of manufacturing. AI systems manage the entire workflow, from optimizing print schedules and detecting defects in real time to anticipating maintenance needs. Meanwhile, robotics handle all the physical work: they pick and load materials, transfer parts between machines, and perform automated post-processing. This seamless collaboration removes human bottlenecks, increases production speed, and guarantees consistent quality at a scale that was previously unimaginable. It elevates 3D printing from a prototyping tool to a genuine solution for industrial-scale production.

Further information on Apollon3D can be found on the company’s website.