July 2025 — MASTERLY has reached a major milestone, completing the development of its next-generation collaborative robotic systems. With one year left before the project ends, the final prototypes are ready to be tested in real factory environments.

We are helping to shape the future of manufacturing by designing robotic systems that can safely and efficiently work side-by-side with humans. They combine mobile bases and robotic arms with advanced safety features like laser scanners and smart sensors to avoid collisions and ensure safe interaction with human workers. With all the main technologies now complete, the MASTERLY project is preparing to demonstrate its solutions in three real-world industrial pilots – at DECATHLON, KLEEMANN, and AERNNOVA.

KER#1 Robotic cell for flexible material handling | DECATHLON use case

Key components of this approach include:

🔸A𝐮𝐭𝐨𝐧𝐨𝐦𝐨𝐮𝐬 𝐫𝐨𝐛𝐨𝐭𝐢𝐜 𝐬𝐲𝐬𝐭𝐞𝐦 equipped with a flexible, sensor-integrated gripper and an advanced vision system.

🔸Detection of product dimensions and identify the optimal grasping points for efficient handling.

🔸 Product data is processed to calculate precise motion trajectories, which are seamlessly communicated to the robot for execution.

KER#2 Robotic mobile system for electrical cabinet assembly | KLEEMANN use case

Key components of this approach include:

🔸𝐀𝐮𝐭𝐨𝐦𝐚𝐭𝐞𝐝 𝐆𝐮𝐢𝐝𝐞𝐝 𝐕𝐞𝐡𝐢𝐜𝐥𝐞𝐬 (𝐀𝐆𝐕𝐬) equipped with collaborative arms for seamless human-robot collaboration.

🔸𝐀𝐮𝐠𝐦𝐞𝐧𝐭𝐞𝐝 𝐑𝐞𝐚𝐥𝐢𝐭𝐲 (𝐀𝐑) interfaces for intuitive control and operator assistance.

🔸𝐀𝐈-𝐝𝐫𝐢𝐯𝐞𝐧 𝐚𝐥𝐠𝐨𝐫𝐢𝐭𝐡𝐦𝐬 𝐟𝐨𝐫 𝐩𝐞𝐫𝐜𝐞𝐩𝐭𝐢𝐨𝐧 𝐚𝐧𝐝 𝐝𝐞𝐜𝐢𝐬𝐢𝐨𝐧-𝐦𝐚𝐤𝐢𝐧𝐠, optimizing logistics and assembly processes.

KER#3 Smart crane system for large material handling | AERNNOVA use case

Key components of this approach include:

🔸𝗔𝘂𝘁𝗼𝗺𝗮𝘁𝗲𝗱 𝗺𝗲𝗰𝗵𝗮𝘁𝗿𝗼𝗻𝗶𝗰𝘀 for part gripping, handling, and high-accuracy positioning

🔸Seamless 𝗵𝘂𝗺𝗮𝗻-𝗼𝗽𝗲𝗿𝗮𝘁𝗼𝗿 𝗶𝗻𝘁𝗲𝗿𝗮𝗰𝘁𝗶𝗼𝗻 𝘃𝗶𝗮 𝗮𝘂𝗴𝗺𝗲𝗻𝘁𝗲𝗱 𝗿𝗲𝗮𝗹𝗶𝘁𝘆 (AR)

🔸𝗦𝗺𝗮𝗿𝘁 𝗰𝗿𝗮𝗻𝗲 with path-planning sensors and anti-swing algorithms

🔸 Automated part 𝗴𝗿𝗮𝘀𝗽𝗶𝗻𝗴 𝗽𝗼𝗶𝗻𝘁 𝗰𝗮𝗹𝗰𝘂𝗹𝗮𝘁𝗶𝗼𝗻 𝗮𝗻𝗱 𝗔𝗥 𝘃𝗶𝘀𝘂𝗮𝗹𝗶𝘇𝗮𝘁𝗶𝗼𝗻

🔸High-precision 𝗮𝘂𝘁𝗼𝗺𝗮𝘁𝗲𝗱 𝗳𝗶𝗻𝗮𝗹 𝗽𝗼𝘀𝗶𝘁𝗶𝗼𝗻𝗶𝗻𝗴

🔸𝗠𝗼𝗻𝗶𝘁𝗼𝗿𝗶𝗻𝗴 𝗼𝗳 𝗳𝗼𝗿𝗰𝗲𝘀 in the attaching anchor points

List of Other Exploitable Results

OER#4 Workflow controller | owner CASP
OER#5 Flexible robotic arm for picking operations | owner COMAU
OER#6 Modular gripper for handling rigid and flexible materials, with integrated AI control | owner IIT
OER#7 Human Tracking and Collision Avoidance | owner LMS
OER#8 Autonomous modular AGV/mobile robot platform that can accept a variety of robot arms | owner COMAU
OER#9 Dexterous gripper for AI-enabled handling of rigid parts | owner TF-CC
OER#10 Impedance control for autonomous pick, place and assembly operations | owner TEK
OER#11 Localization, motion planning and collision avoidance | owner RWTH
OER#12 Dynamic task and actions planning and allocation s/w | owner LMS
OER#13 Vision based real-time object geometry estimation for safe handling and transportation | owner UNIKIEV
OER#14 Modular fixture element with integrated sensors and actuators | owner TEK
OER#15 Smart crane with integrated control algorithms for flexible components handling | owner TEK
OER#16 Sensors and actuators for intelligent stationary fixtures | owner TEK
OER#17 AR application for human operator support and robot control | owner LMS
OER#18 Digital Twin visualization for sportswear logistics | owner RWTH
OER#19 Digital Twin visualization for elevators manufacturing | owner LMS
OER#20 AI Vision and CAD based solution for automated robot programming | owner LMS