The Caracol AM Heron 300 is a large-scale 3D printing platform within the Heron AM LFAM range, built to produce large components, complex geometries, and customised industrial parts with lower material use and flexible material choices. It combines additive manufacturing technology, engineering expertise, and an integrated process approach to support demanding production requirements across advanced industries.

Large-scale additive manufacturing platform

Caracol AM positions the Heron AM platform as a solution for manufacturing parts with no limits in size across a broad set of advanced additive manufacturing applications. The platform is designed around state-of-the-art industrial printing technologies and a robotic additive manufacturing system for large-format production.

Integrated process across the value chain

The Heron 300 is supported by an integrated process that combines core competences across materials, hardware, software, and industry knowledge. Caracol also highlights supplier partnerships and application know-how as part of the overall manufacturing approach.

Engineering for additive manufacturing

The Heron AM workflow is built around advanced design for additive manufacturing methods. Caracol specifies the use of generative design, parametric design, and topological optimization to improve part geometries and expand what can be produced with large-scale AM.

Solution-oriented manufacturing support

The platform is presented as part of a solution-driven process that starts with identifying client needs and manufacturing opportunities. Caracol states that solutions are customised to help clients adopt additive manufacturing in a way that addresses demanding industrial requirements.

Key features and benefits of the Heron AM platform

HERON AM, described as Caracol’s LFAM platform, was developed to provide a range of manufacturing benefits tied to scale, geometry, cost control, and material efficiency.

Print large-scale components

Caracol’s robotic system is built to print advanced parts with no scale limits, up to 12 m. This makes the platform suitable for applications where conventional machine envelopes are too restrictive.

Produce more complex parts

Software algorithms combined with a 6-axis robotic arm allow the system to manufacture a wider range of applications and more complex geometries. This is particularly relevant when part shape and motion freedom are limiting factors in standard gantry-based setups.

Lower operating costs with production flexibility

The Heron platform is described as highly flexible and adaptable to productive needs. Caracol states that it operates efficiently with low operating costs without compromising quality and performance.

Reduce raw material cost through material flexibility

The system works with a wide range of composites, from advanced techno polymers blended with fibres such as carbon or glass to recycled material shreds. This broadens material selection for both technical performance and cost management.

Cut material waste in production

Caracol reports that the platform can reduce raw material used in production by up to 60% by using only the material needed and printing without supports. The ability to process recycled material also supports waste-reduction strategies.

Integrated platform architecture

The Heron AM integrated platform brings together the core hardware and control elements needed for large-format robotic additive manufacturing.

• 1. Extruder
• 2. Robotic arm
• 3. Printing bed
• 4. EIDOS manufacturing software
• 5. Material feeding system
• 6. Perimetral protections
• 7. Extruder control panel
• 8. Robot control system

Materials processed by the Heron AM platform

The system is built to process a wide range of polymers and composites for structural, tooling, flexible, exterior, and recycled applications.

PP GF for lightweight structural parts and tooling

PP GF is described as lightweight with good mechanical properties. Caracol notes that it can replace glass fibre and aluminum in marine structural parts or aerospace molds and tools.

PA CF for stiff, lightweight parts exposed to medium heat

PA CF is identified as stiff, flame-retardant, and lightweight. It is suitable for high mechanical performance and light structures operating in medium heat environments.

PC CF for thermal and mechanical performance

PC CF is described as offering strong thermal and mechanical properties. Caracol also states that the material has been qualified for mid-temperature autoclave processes.

TPE FLEX for rubber-like large-format parts

TPE FLEX is presented as a high-strength, flexible elastomer for large-scale rubber-like parts. Example applications include topologically optimized pliable structures such as cushions and seating.

PET-G for exterior structures and prototyping

PET-G is described as high impact, chemical resistant, and UV resistant. Caracol identifies it as suitable for PVC-like exterior structures and prototyping applications.

Recycled materials for circular manufacturing

The platform can work with a wide variety of recycled materials, including grinding waste, parts at the end of their life, client waste, and purchased upcycled material. This supports manufacturing workflows that prioritise material recovery.

Manufacturing outcomes and process improvements

Caracol lists several measurable production benefits associated with the Heron AM platform and its manufacturing approach.

• Up to 70% product cost savings
• Up to 60% raw material saved
• Up to 50% weight decreased
• Up to 2x lead time reduction
• Full customization at single unit level
• Recycle waste from production
• Inventory & logistics costs reduction

Use cases for large-format robotic additive manufacturing

The Heron 300 is suited to manufacturing scenarios where part scale, weight reduction, geometry freedom, and material efficiency matter. Based on the materials and benefits listed, relevant use cases include marine structural parts, aerospace molds and tools, mid-temperature autoclave tooling, lightweight structures exposed to heat, exterior structures, prototyping, flexible seating elements, and production workflows that make use of recycled feedstocks.

Production support throughout the manufacturing process

Caracol states that it accompanies clients throughout the production process. The overall offer combines technology, integrated process knowledge, engineering methods, and solution customisation to support additive manufacturing adoption from requirement definition through production execution.