Haddington Dynamics: The Open‑Source, High‑Performance Dexter 3‑D Printed Robot Arm

In 2015, Haddington Dynamics—a Las Vegas robotics pioneer—introduced the Dexter, an affordable, open‑source robot arm that can pick and place, grip, and even print replicas of itself. The platform has attracted high‑profile clients such as NASA, Toshiba, and GoogleX.

A focus on strength and quality

Early prototypes were built from laminated wood, paper, and laser‑cut components, before shifting to PLA 3‑D printing to reduce costs. However, PLA proved too brittle, demanding additional reinforcement and ultimately proving an impractical material choice.

Guided by a trusted partner, the team pivoted to industrial‑grade 3‑D printing. “NASA advised us to try a Markforged system,” recalled Dexter’s inventor Kent Gilson. “Within three weeks of acquiring the Mark Two and Onyx Pro, we redesigned the arm using a carbon‑fiber lay‑up, drastically reducing part count from 800 to just 70.”

3D printed custom end effectors

Previously, each Dexter cost heavily and required a week of assembly from PLA parts. Today, a full robot can be assembled in a single day, with both material and labor costs slashed. Producing roughly ten units monthly, the investment in Markforged printers has already paid off. “Each output recoups the ROI, fundamentally reshaping our manufacturing model,” notes CEO Todd Enerson.

Custom end effectors are a key feature of the Dexter kits. While early models shipped with a standard set, Haddington now prints task‑specific fingers tailored to each application. Engineers scan the target part, then fabricate precision grips that dramatically improve picking speed and accuracy. The modular design also lets customers swap in alternative end effectors, giving them full control over the arm’s payload capabilities.

The future of 3D printing and robotics

For Kent, the Markforged printer’s tolerance is its most compelling advantage. When fabricating 3 mm posts for harmonic‑drive mounts, traditional machining would have caused wall swelling, requiring re‑engineering. The Markforged build produced a 2.99 mm post—an accuracy that surpassed conventional machining. “The precision was astonishing,” Kent remarked. The seamless workflow even allows Haddington to ship a finished Dexter directly from the print bed. “We delivered a robot to Toshiba that was ready to use straight out of the printer,” he added, noting the clients praised the polished surface finish.

Today, the Dexter is constructed almost entirely from Markforged components. Haddington’s long‑term vision is a self‑assembling robot that prints and assembles its own parts. The system can pause a print to embed electronics, making this ambition increasingly realistic. As production scales, we expect to see a growing fleet of Dexters—all built with the same high‑precision Markforged technology.

Curious about the strength of Markforged prints? Request a free sample part today!