The dream of humanoid robots interacting naturally with us is changing from science fiction to the reality we’re soon to enter. This new generation of robotics requires a new degree of excellence in manufacturing. Humanoid robots require, unlike industrial robots, a different combination of lightweight, extraordinary strength and an articulation that closely resembles the human body. The challenge for engineers and designers in this field will not so much be in the code and algorithms, but in the tangible realization of their designs. This is where the precise manufacture of custom robot parts will serve as the bridge that connects the digital design and the functional, reliable machine.
The success of any humanoid platform will depend on the performance of its core components. Off-the-shelf components can’t meet the exacting demands for unique geometry, weight, and tolerance, (which will vary by custom robot parts manufacturer, depending on their capabilities) required for a bipedal robot. This makes the association with a specialized manufacturer, capable of turning out high precision robotic components, a not only a possible procurement step, but a strategic engineering decision.
Engineering the Anatomy: Key Custom Robot Parts and Their Machining Requirements.
From the engineering standpoint, a humanoid robot is a series of interconnected systems that require precision CNC machining in order to achieve the required performance specifications.
1. Actuators and Joint Assemblies:
These joints, hips, knees, shoulders, elbows, etc., are the muscles and tendons of the robot, These are often based on custom actuators, harmonic drive systems and output flanges.
Manufacturing Requirements: These components will require exceptional CNC machining for robotics. The actuator housings will need to be lightweight to minimize inertia, yet rigid enough to take some very high torque without deflection. Particular tolerances are very important to assure the perfect alignment of bearings and gears, which are a must to avoid backlash and premature wear. This will not be attainable in the degree required without the use of high precision robotic components, machined in high strength aluminum alloys or titanium.
2. Structural Frames and Links:
The “skeleton” of the robot complete, limb links, torso supper structure, etc., must be extraordinarily strong and lightweight. This makes them a perfect candidate for complex designs which can be topology optimized which again can only be produced by means of multi-axis CNC machining.
Manufacturing Requirements: Custom robotic arms links and leg links will often involve deep pockets, internal channels for wiring and complex surfaces. 5-axis CNC machining will allow to manufacture these components from solid billets of the material being used, assuring that the most optimum grains and strength will be attained, and imposed weaknesses resulting from welding or assembly will be eliminated. The resulting structure will be a frame that will produce a robot that will maximize the strength-to-weight ratio.
3. End-Effectors (Robotic Hands) and Sensor Support Brackets:
The complexity of the robotic hand is stupendous, which means that many small complex components must work together. There are also sensor mounts for LIDAR systems, cameras and IMUs that have to work together. These must be very accurately placed and dampened so that no vibrations occur.
Manufacturing Requirements: This must be the province of Swiss-type CNC lathes and high speed milling. Custom robotic gears, tiny finger linkages and complex mounting brackets for sensors can be manufactured with the mid-0.005” tolerances required with smooth action. The ability to fabricate custom robot parts from engineering plastics like PEEK or UHMW, besides metals, is often an essential design feature in these applications.
4. Custom Brackets and Mounting Solutions:
In a crowded humanoid chassis, every component needs a lightweight, secure, and perfectly fitting mount. Custom robot components like this are ubiquitous and essential for the integration of systems.
Manufacturing Business: Robot parts can be manufactured on-demand to iterate these brackets. Use of CNC machining for robotics allows for designs to have perfect mounts done in days, speeding the R&D cycle so motor, controllers and sensors can be secured in their best positions.
The Business and Market Implication: How Relevant Your Manufacturing Partner As.
The humanoid robotics market is not just a technology race but also a commercial one. Speed, reliability and scalability are the issues here.
Rapid R&D Cycles: The design of a humanoid robot is an iterative process. A manufacturer who supplies prototype to production robot parts is invaluable. The ability to quickly produce a revised joint design or new link structure allows your team to test and learn quicker, greatly decreasing your time to market.
Reliability for Commercialisation: Failure of a robot in the field is a liability to the brand. Precision robotic assembly components made to stringent quality levels (as ISO 9001:2015 and AS9100) will ensure reliability. Precision consistent CNC machining means that the thousand part will operate identically to the first, allowing confidence to be built up with early adopters and investors.
Scalability from Prototype to Production: A start-up company may need 10 sets of parts for a beta platform but a successful company will need 10,000. Partnering with a manufacturer experienced in high volume precision robotic parts will allow seamless change from prototyping. The myriad techniques of DFM (design for manufacture) techniques and the dedicated creation of CNC machining cells for high volume production parts ensure that no bottle-neck in manufacturing will occur when scale is reached.
Supply resilience: The last few years have seen the fragility of our worldwide supply chain. A domestic or expressly strategically placed manufacturer who can produce custom robotic arm parts and other significant components will provide much needed supply chain security whilst not hampering dependence offshore and giving much needed diminishment of levels of disruption to the supply side.
Material Selection: Balancing Performance with Practicality.
The material selected is an integral part of the design process in custom-manufactured robot parts.
Aluminium 6061 & 7075: The workhorses of the industry. 6061 is an excellent balance of strength, ease of machining and cost. 7075 offers strength comparable with many steels so is ideal for high-stress components like humanoid robot joint parts.
Titanium (Ti-6Al-4V): For the most operator face requiring the highest strength to weight ratios, like critical weight-bearing structures. Its biocompatibility is also good for robots designed to be in close association with humans.
Engineering Plastics (PEEK, Delrin): Electrical insulation, wear resistance and diminished noise problems are the things these are valued at, being ubiquitous in the field of precision robotic gears, bushes, low friction components for end-effectors.
In Conclusion: Partners for a Robotic Future
Constructing a humanoid robot is one of the most complex engineering endeavors ever faced. Its physical components must be of such exactness, precision and quality that unless these are basic to it, the rest of the robot will fail. By selecting a manufacturing partner with extraordinary skill at custom robot parts manufacturing, you are doing more than putting in an order. You are, right from the beginning, giving a pledge of quality and performance to the very skeleton of the robot.
To bridge the gap between the ideas for a robot and having it ready for sale involves a bridge built on an astounding engineering skill, business, and a meeting of minds concerning the future. This bridge will be composed of true custom robot parts correctly made. Are you building the future of humanoid robots? Get in touch with Falcon CNC Swiss today about it. Our manufacturing experience in high quality, precision, reliable custom robot parts is your asset in an all-important race. Let us help you convert some of your new and fantastic designs into realities.
