I have some more exciting progress to document
Chopper now has all the parts for his first leg printed, which means I can show how I designed the parts for assembly.
I’ve put together a short video below for you all that shows it all and how all the parts fit together, and I have also posted photos of each step accompanied by a written description.
To start off with these are all the parts ready for assembly. This includes the aluminium leg that I showed earlier in the thread, all the 3D printed parts that sleeve around the Aluminium leg and then the custom shoulder bolts for mounting the leg to the frame.
First step is to sleeve this cylindrical piece down the leg. I designed this to have slots underneath that allow the printed part to have a spot on friction fit onto the 3mm aluminium plates that make up front and backside side of the aluminium leg.
Next up is the middle detail section, this simply slides down the leg and then sits neatly inside the cylindrical piece that's already seated at the bottom.
Now that these first two printed parts are on, it's time to insert the shoulder bolts.
Following the shoulder bolts, the backing plate for the top shoulder piece is inserted along with the shoulder to frame connection hub.
The next stage involves attaching the struts that run up either side of the leg. I've designed these to incorporate an aluminium rod the runs the length of the inside of the part for strength. This rod also protrudes from either end which allows for friction fitting it to the other parts.
As demonstrated below, the producing pins pop straight into the pre-existing mounting holes that are on the cylindrical bottom piece.
With all the parts above sorted it's time for sliding on the main shoulder piece.
I'm particular pleased with this as it has grooves so that it slides seamlessly past the shoulder bolts and around the backing plate on the other side.
As you can see here the shoulder pieces it designed to sleeve around the aluminium leg and the backing plate/connection hub perfectly.
The purpose is this is it allows the shoulder piece to be slid off at any time so I can quickly and easily access the shoulder bolts which is very handy!
And then of course, here's the assembled leg ready to be attached to the frame and the corresponding outer foot
Thanks so much mate! I'm really pleased with how it's all come together. And that's a fantastic question, I also had those concerns. With the specific 3D printed part that acts as the main coupler between the leg and the body I bumped up the infill percentage to help add some extra rigidity and see if that would do the trick. So far, it's working great and far better than I thought it would. It's a hefty chunk of plastic considering it was 3D printed, but that increased infill percentage is working wonders.I'll keep the thread posted as to whether if it fails as I'm interested to see how it holds up! If it fails, I'll resort to a different material
And while I'm at it, here's a quick video of him in motion I am pushing him around, but it's awesome to see Chopper properly rolling!
Some more progress on chopper, he now has proper feet.
I was able to fit the entire part in as a single piece 3D print. This was the largest part individual I've printed so far on my printer and I was super impressed with the quality and minimal warping for the size.
In the first photo you can see it as it just finished printing with all the supports intact still:
Next comes some basic clean up, removing all raft with my scraper followed by the printing supports:
And then here's how the part looks! Very pleased with the result.
Only part left for the door shells is some small trim/detail pieces and the 'battery boxes' that connect to the sides.