Wednesday, May 25, 2016

R2-IQ: Printed Parts

R2-IQ: 3D Printed Parts

Complete Artoo Head
I just received 16 printed parts for R2-IQ.  The process for getting them was a long story...

I designed a couple pieces in SnapCAD (CAD software for VEX IQ) and posted them on the web, asking if anyone could create an stl file.  Within a day, I had a couple offers, and one very good file from David Knerr.

After we made a few tweaks of two parts, Davin printed the parts in one of Purdue Polytechnic's labs.
Assembly of Head
The two parts consist of a triangle-shaped piece (4x) and a diamond-like polygon (12x) which together fill all the area in R2's head.

The design of these parts allowed me to remove much of the internal structure that was required to create the original shape.

Head on body

The most time consuming part of assembling the new head was putting 240 pins into the 3D printed pieces.

Once it was complete, the new head has a lot less panels inside, and is much more rigid than the previous one.

The head is mounted on four rollers, which previously only raised the middle enough to stabilize it.  Now, there is actually a small gap between the head  and the body.

The new design drives a couple small wheels that the head is sitting on.  It's much freer to turn, and slip when people try to turn it manually.
The drive for the head was originally a motor & worm gear that turn an axle connected to the head.  This put a great deal of torque on a couple small pieces, especially when people would walk up and try to turn the head by hand.

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