Life-size BB8

I wanted to see if I had the skills of those droid builders a long time ago in a galaxy far far away… and what poses a more unique engineering challenge than the newest droid companion: BB8

First full prototype rolling under its own power.

The design started with hand sketches as I had an idea come to me.
BB8.jpg
 
 
 

The requirements

After the hand sketches, the overall size was determined. General space claim completed.

The Concept

Developing the placement for the different subsystems and how they interreact.

The Prototype

The frame was designed based on the generative design results. The drive system was also finalized in this step.

The Iteration

After printing the prototype and seeing the initial operation the second iteration was born. In this version weight mechanism that allows the tilt and spin motions was overhauled to be more efficient

Drive System and Frame

  • Frame and Drive System

    The frame is 3D printed PLA+ The drive system is robustly mounted between two-angle aluminum bolted to the frame.

  • Main Frame Assembly

    Main Frame Assembly

    The singular printed part lends strength and dimensional accuracy to the design. The bearings are press-fit into the frame

  • Joints and Wheels

    This L-Joint allows the load to do be distributed across the entire cross-section of the part while also supporting and preventing the shear forces. The Radial flange bearing is also being used to distribute the weight of the robot while allowing the wheel to run smoothly.

  • 3D Printed Frame piece

    The part was printed in this orientation to insure hole accuracy and relative distance. The part was optimized to be printed on the bottom face for ease of support removal.

  • Drive System

    The drive system is run by a 12V DC motor controlled by an Arduino and Victor speed controller. The DC motor is connected to a 4:1 planetary gearbox which is then input into a 3D printed resin transfer case to drive the Hex axle and drive wheels.

  • Shell and Rings

    The outer shell prototype is made from thermoformed Kydex then adhered to the Rings. The Rings are printed and assembled. The final model will be fiberglass for increased rigidity

  • Shell Panels

    The shell panels are first brought up to temperature and then pressed into this 3D Printed fixture with aluminum foil to help with the heat.

Used generative to identify the critical structural location of the frame and then create an easily FFF printed part

BB8 Final model

Weight System [Tilt+Spin]

  • Weight System

    The top axle and the large ring bearing give structure to this system. 5lbs of steel rod is placed in the counterweight to give it enough momentum to spin BB8 about its central axis and to tilt from left to right.

  • Weight System Spin

    The DC motor spins a Double helix gear set to rotate the lazy suzen mounted with 5lbs of Steel rod.

  • Weight Rotation [Tilt]

    Weight Rotation [Tilt]

    Large aluminum gear is attached to 3D-printed arms to rotate around the top hex axial.

  • Rotation Motor

    3D printed on a SLA printer out of a water washable resin. The bracket has nuts pressed into the part

  • Spin Motor mount

    3D printed SLA motor mount for the rotational motor. Printed on Creality ld-002r

Some times you just have to try it without a speed controller

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Reel Scan