Robotics Prototyping: The Complete Guide
Robotics starts with a concept and turns into a reality in different stages of development. The prototyping stage is crucial, and it consists of creating a robotics prototype for testing purposes.
If you are eager to learn about robotics prototyping, the guide below can greatly help. So, let's read.
What is Robotics Prototyping?
Robotics prototyping is a process in which early models of robotic systems are created for testing.
The design is tested for its appearance, performance, and functionality, followed by the creation of different components. These components are also evaluated based on their functionality.
The commonly tested components of robotics at the prototyping stage consist of control system sensors and actuators. Creating a prototype allows us to look for improvements, if any, and if it is a cost-effective method before beginning the actual final production.
Importance of Robot Prototyping
There are multiple reasons which make the process of robot prototyping an important one, and some of these aspects are as follows:
Cost-Efficiency
Prototyping for robots allows developers to identify any design flaws at an early stage, which leads to reduced costs that may arise later on. This early testing ensures that mistakes are avoided in the final manufacturing.
Less Risk
The robot prototyping also allows developers to identify any failures in the design, and an assessment of how it will perform in the real world is also carried out. Hence, the risk of any faults in the final robots can be prevented.
Validation of Design
Prototyping allows us to validate the design of the robot and its components. It allows an opportunity to check everything integrated together to see how it performs. This way, the design can achieve validation of whether it meets the project requirements or not.
Methods of Manufacturing a Robot Prototype
Manufacturing a robot prototype requires various methods of production, which are discussed below.
Maquinação CNC
CNC machining helps manufacture components that are precision-oriented and repeatable. It is suitable for the prototyping process because it creates components with tight tolerance.
CNC machining is a versatile process and can work with many different materials as needed for robotics prototyping.
The best part about Maquinação CNC is that it is a flexible process and helps create iterative designs in less time. Moreover, the production runs can be scaled when needed without any requirement to opt for other manufacturing methods.
The process works with complex components and even offers to create parts with tolerance in microns.
Impressão 3D
3D printing is a process in which layers of material are deposited over each other, creating components using different materials. It is used for manufacturing 3D objects and is widely used at the prototyping stage of robotics.
3D printing allows us to create parts that are complex, especially the channels required in objects internally or have complex features. The process of 3D printing is relatively fast, and components can be created in a span of a few hours.
3D printing is even compatible with most materials, thermoplastics, and metals and offers cost-effective prototyping as it is suitable for low-volume production.
Moldagem por injeção
Moldagem por injeção is used in rapid prototyping, which helps in creating components using molds. It is suitable for mass production but also works well with rapid prototyping.
It is suitable for manufacturing components that require rigidity and strength and hence is used for robotic prototyping.
The process of injection molding is a bit expensive because the cost of creating mold is high, and hence, small-scale production may not find it as cost-effective. However, if the budget allows it, it will help manufacture components for robotics prototyping.
Fundição sob vácuo
Vacuum casting is a process in which a silicon mold is created from a master mold and then is used to cast parts under a vacuum.
The process is highly suitable for robotics prototyping when small batch runs are needed one after the other. It ensures excellent surface finishing and also can be used with a wide range of materials.
It is a quick option compared to injection molding and can help reduce prototypes in a small quantity compared to traditional methods. Even it is economically suitable when it comes to creating small batches.
Fabrico de chapas metálicas
Sheet metal fabrication helps in robotics prototyping. Sheet metal fabrication helps manufacture components that are durable and offer heat dissipation. It is a scalable process and is followed by another process to achieve the final components.
It also offers tight tolerance and precise components. It is mostly opted for robotics prototyping for components that require thermal stability and structural integrity.
Materials Options for Robotics Prototyping
The process of robotics prototyping uses different materials for different components. Some of these material options are as follows:
Aço inoxidável
Stainless steel is opted in robots for its corrosion resistance and strength. The components of stainless steel are manufactured through sheet metal fabrication and CNC machining.
Alumínio
Aluminum is a lightweight material and is highly machinable. Hence, it can be used to manufacture robotics using sheet metal fabrication, CNC machining, and rapid tooling.
Delrin
Delrin is lightweight, strong, and has low friction. It is used to manufacture robotics components using injection molding and CNC machining.
Urethane
It is quite cost-effective and transparent. It is suitable for vacuum casting to manufacture robotic parts.
Silício
Silicon is used in combination with injection molding to manufacture durable and flexible robot components.
Surface Finishes for Robotics Prototyping
Once the components for robotics prototyping are machined and manufactured, some of them may require additional surface finishing.
The different surface finishing options available for robotics prototyping are as follows:
- Anodizing: The robotic components that may be subjected to harsh conditions may pass through the anodizing process as it enhances its wear and corrosion resistance.
- Jato de esferas: The process of bead blasting involves adding a uniform surface finish, which is matte on the component, and removing any imperfections. It is suitable for the surfaces of the robots that are displayed.
- Powder Coating: Powder coating creates a layer of protection on the components, enhancing their finishing and adding uniformity.
- Electroplating: A thin layer of metal is created through electroplating on the surface of the components. It helps in reducing friction and ensuring enhanced electrical conductivity.
Factors to Consider When Making Robot Prototypes
When creating prototypes for robotics, some of the factors that are important to consider are as follows:
Seleção de materiais
The material chosen for the robot is associated with its anatomy, and you need to select the material while keeping this in mind. Metal is a durable material, plastic offers flexibility, and composites are known for offering both.
However, the selection will be based on cost, performance, and the method used to manufacture the final robot.
Complexity of Design
Robotics involves highly precise components that are complex and need tight tolerance. The manufacturing technique chosen should align with the design intricacy and the required precision.
Components that are highly complex are usually manufactured through CNC machining in robotics prototyping.
Volume de produção
The volume of production is also a consideration, as some methods selected for robotic prototyping may not be cost-effective due to the low volume of production.
Hence, it is suggested that cost-effective methods be opted for based on production volume.
Market Speed
Robotics is an evolving development that needs to be floated in the market as soon as possible. Hence, rapid prototyping may suit in this regard to boost the development cycle.
Scalability of Design
Robotics is constantly evolving, and the manufacturing method should be scalable so that it can update changes immediately.
Conclusão
Robotics prototyping is a highly evolving industry, and keeping pace with it requires carefully considering the designs, materials, and manufacturing processes.
The guide above highlights all the important details regarding robotics prototyping, and you probably have understood them clearly.
Start Your Robotics Prototyping Projection with DEK
If you have a concept of robotics in your mind and want to have a perfect prototype created to assess the design and concept, contact us at DEK.
We will help you create a prototype using the relevant materials and processes– ensuring scalability. We have a team of expert engineers with relevant knowledge and skills in working with robotics prototyping. So, contact us today.
