Max Robotics — Global Service Robot Directory + US Certification

About

Todd E. Sparks is a leading researcher in advanced manufacturing, specializing in industrial robotics, additive manufacturing, and hybrid manufacturing processes. His work focuses on integrating robotic systems with material deposition technologies to enable large-scale, high-precision fabrication. Sparks’ most influential contribution is the design of a Fused Pellet Modeling (FPM) system, which replaces traditional filaments with granular materials for large-scale additive manufacturing—a breakthrough that has garnered 53 citations. He has also developed novel methods to evaluate and improve industrial robot accuracy by analyzing joint angle errors and stiffness mapping, directly addressing the kinematic and load-induced deformations that compromise manufacturing precision. Beyond structural applications, Sparks has pioneered robot ink deposition on curved surfaces, using adaptive compensation algorithms and B-spline surface theory to enable precise additive manufacturing on complex geometries. His work is foundational for scaling hybrid manufacturing processes that combine additive and subtractive techniques, with significant implications for aerospace, automotive, and custom fabrication industries. Through his systematic analysis of robot trajectory accuracy and stiffness, Sparks has provided critical frameworks for enhancing the reliability and capability of industrial robots in demanding manufacturing environments.