[Paper Review] Designing, 3D Printing of a Quadruped Robot and Choice of Materials for Fabrication

Akash Maity, Koustav Roy+1 more|arXiv (Cornell University)|Jun 15, 2019

Robotic Locomotion and Control2 references4 citations

TL;DR

This paper presents a design and additive manufacturing approach for a 3D-printed quadruped robot using CAD modeling and Fused Deposition Modeling (FDM) 3D printing. It evaluates material performance, finding that 3003 aluminum alloy legs outperform ABS by providing superior strength-to-weight ratio, structural stability, and compatibility with high-torque servos, enabling improved locomotion stability despite power supply limitations.

ABSTRACT

Purpose-This paper is based on design of a quadruped robot and manufacturing it with 3-D printer followed by its detailed analysis. It focuses on the advantages of additive manufacturing rather than conventional manufacturing techniques and also highlights its limitations. The consequences of choice of different materials for 3-D printing are evaluated in this report. Design/methodology/Approach- The parts were designed in CAD software and made into Stereo lithography files, which were fed into the 3-D printing software. They were printed with the selection of ABS material. Low torque servos were employed in the beginning of the assembly and were controlled with the Arduino Uno micro controller. Findings- The versatility of legged robots require materials with high strength to weight ratio, where 3003 aluminium alloy sheets proved to be a better choice than conventional ABS. The ABS legs buckled under load and proved to be an inferior material choice for fabrication. The aluminium sheet fabricated legs not only imparted structural stability to the robot but also allowed in selection of more powerful servos for added strength.The bot could now achieve significant level of stability. Research Limitations/Implications- The power supply used for powering the bot was of SMPS type of power supply which made it less mobile. Due to the huge demand of current by the high torque servos used later, the power supply became a huge limitation which can be overcome by applying Lithium ion batteries. Practical Implications- The bot can be used for SLAM and autonomous navigation in areas where it is almost impossible for humans to access into. Originality/Value- This paper shows a concrete study on efficacy of quick CAD designing and rapid fabrication.

Motivation & Objective

• To develop a low-cost, customizable quadruped robot using additive manufacturing for rapid prototyping.
• To compare the mechanical performance of 3D-printed ABS versus machined 3003 aluminum alloy in robot leg structures.
• To assess the impact of material choice on structural stability, servo performance, and overall robot mobility.
• To identify limitations of current power supply systems in high-torque servo-driven robots.
• To demonstrate the feasibility of using 3D printing for rapid fabrication of functional legged robots in robotics research.

Proposed method

• CAD software was used to design all robot components, including legs and structural frames, followed by STL file export for 3D printing.
• Fused Deposition Modeling (FDM) 3D printing was employed using ABS plastic for initial prototyping.
• 3003 aluminum alloy sheets were machined into leg components as an alternative to 3D-printed ABS for comparative testing.
• Low-torque and later high-torque servos were integrated into the robot’s joints for actuation.
• An Arduino Uno microcontroller was used to control servo movements and coordinate gait patterns.
• Power supply was provided via an SMPS unit, later identified as a mobility constraint due to high current draw from high-torque servos.

Experimental results

Research questions

• RQ1 How does the choice of 3D-printed ABS compare to machined aluminum alloy in terms of structural integrity under load for robot legs?
• RQ2 To what extent does material selection affect the stability and performance of a quadruped robot during locomotion?
• RQ3 What are the mechanical limitations of using ABS in load-bearing robot components under dynamic servo actuation?
• RQ4 How does the use of high-torque servos impact power supply requirements and system mobility?
• RQ5 Can additive manufacturing combined with lightweight, high-strength materials enable improved robot functionality over conventional 3D-printed plastics?

Key findings

• 3003 aluminum alloy legs demonstrated significantly higher structural stability compared to 3D-printed ABS legs, which buckled under load.
• The aluminum alloy legs allowed the use of more powerful servos, resulting in improved locomotion stability and performance.
• ABS material proved inadequate for load-bearing applications due to low yield strength, leading to mechanical failure during operation.
• The SMPS power supply was identified as a major limitation due to high current draw from high-torque servos, restricting mobility.
• The study confirms that material selection is a critical factor in determining the mechanical performance and reliability of 3D-printed robotic systems.
• The integration of rapid CAD design and 3D printing enables fast prototyping, but material properties must be carefully evaluated for functional deployment.