IV. Manufacturing and Assembly - AG

The leg mechanisms were manufactured using the Full Spectrum 48x36" 140W CO2 Lasers at TIW. Before the leg mechanisms were cut, CAD models were made using Solidworks. The design process was iterative, and we created multiple legs before finetuning our design for the final iteration.

Initial CAD Model

Initial Prototype links

After we made our first legs, we realized that the simplification of making the two triangular links would help with manufacturing and lower costs by reducing the number of necessary. The first prototype also helped us dial in our tolerances for press fitting the bearings and dowels. We changed our CAD model to address the issues we found from our first prototype.

Revised CAD Model

Second Prototype

The second prototype went together well, and it was time to build the final prototype.

Assembling the Leg Mechanism

Final Prototype

The laser cutters allowed us to quickly make adjustments and new prototypes. If the design were to be implemented in more expensive materials, this early prototyping would still be extremely useful for saving time and money. The laser cutters offered a level of precision perfect for a proof of concept and offered good testing to build on for any future iterations. The wood press fit tolerances were dialed in using small wooden rounds and then implemented in our prototypes to save material. We used 3/16” inch dowels that press-fit into the 3/16” x 3/8” x 1/8” bearings.