Daedalus

6-DOF Stepper-Driven 3D Printed Robotic Arm

Project Overview

Spurring from the spontaneous and somewhat impulsive idea to build a robotic arm with my incredible software/computer engineer and dear friend, Sean Ray, Daedalus began as simply, "how much could we accomplish with a month left of summer and few resources?"

It was our last summer before college and having spent the first half of summer playing video games and doing practically nothing, Sean and I were itchy to get back into the flow of creating a new project -- and with the typical college roots of returning to Waffle House every couple of days (and sleeping on the couch in between), we planned the different degrees-of-freedom and mechanical operation(s) of the various axes on the arm.

Taking inspiration from Greek mythology, we lovingly named the arm, "Daedalus", meant to signify a sense of precision and accuracy, delicate craftmanship and scrappiness you might associate with such a craftsman of his day. Also, we planned on building a second robotic arm, with a sprightlier and spirited actuation in mind like a young "Icarus", built for speeds/accelerations and backdriveability.

My Contributions

▹ Conceptualized and digitally developed mechanical operation(s) of each axis on Daedalus
▹ Drafted several full-scale renditions of Daedalus
▹ Designed mechanical prototype entirely in Fusion360 CAD software, built mechanically operational analog
▹ Conducted material and CoM analysis on various joints/assemblies to determine max weight capacity/accelerations
▹ Specified parts to work entirely with available on-hand stepper motors, 3D printed parts, and hardware available thru retailers
▹ Prepared mechanical analog for capstan drive actuation with adequate cord and (temporary) 3D printed belts for prototyping
▹ Assembled full arm and prepared wiring for connection to control board/microcontroller

Although the initial version of the robotic arm did not reach full functionality -- primarily due to a lack of thorough initial reasoning and miscalculations in estimating payload capacity and gearbox configurations -- this project proved to be an incredibly valuable learning experience. I gained hands-on knowledge in the assembly process, developed a deeper understanding of manufacturing best practices, and significantly advanced my CAD modeling skills, which are critical for precise design and iteration. These insights have laid a strong foundation for future work, and I am currently in the process of designing a revised model, Daedalus II. This new iteration will incorporate the lessons learned by carefully selecting and integrating commercial off-the-shelf components, such as the SKR Mini E3 V3 controller, while ensuring proper alignment between motor capabilities, driver current limits, and gearbox reductions. Additionally, Daedalus II will benefit from improved manufacturing techniques and streamlined assembly processes aimed at maximizing reliability and performance. Through this iterative approach, I am confident that the revised robotic arm will better fulfill its intended functions and demonstrate a more robust, efficient, and thoughtful engineering design.

In review...