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When you think of durability, you probably think of metals first However, some of the newer plastics offer many advantages over metals when it comes to building robots for competition
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With virtually unmatched impact resistance, outstanding dimensional stability, and crystal clarity, Lexan polycarbonate resin continues to be one of the popular types of materials for use in combat robots The product is a unique thermoplastic that combines high levels of mechanical, optical, electrical, and thermal properties GE Structured Products is one of the leading suppliers of Lexan sheet material
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At a recent BattleBot competition, GE handed out hundreds of hand-sized samples of Lexan 9034 to robot designers, some of whom immediately put it to use on their creations as protective armor or spacing material Technical demonstration videos were on display and product specification sheets were made available Even the BattleBox was designed with four layers of protection using Lexan material to keep the deadly robots and flying parts from injuring spectators Even this material is not impervious to all types of damage, as a large chunk of one of the Lexan panels had a large chunk torn out of it by a wayward robot in a recent match Your local plastics supplier may have the material on hand, can order it, or can direct you to the GE Structured Products division (wwwgestructuredproductscom) nearest you
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Despite Lexan and other materials, metals are the material of choice for most robot structures and armor, and numerous types of metals are available for robot construction While newer experimenters are often confined to using only those materials they can find at the local hardware store, surplus store, or junkyard, we recommend using the highest grades of materials you can get your hands on to construct your combat bots (Appendix B at the end of this book will point out vendors that can help you get the best materials) Metal supply companies are available in larger cities, but many potential robot builders are not familiar with the best metal and materials to use for a particular type of project Although we don t cover modern ceramics, plastics, and composites in this chapter, a plethora of alternative options such as these are available out there The word strong as applied to the various durability characteristics of metals and materials is often misused For example, rather than look for a strong metal, you might want a metal for a particular weapon design that can take a lot of bending after being struck and not break, and you ll find that a piece of spring steel works well for that Another part of your robot might call for a stiff rod, and you select an alloy of stainless steel Your wheel hubs must be light, tough, and easily machined on your small lathe, so you select aluminum alloy 7075 Two nice pieces of brass seem to work fine as heat sinks for your drive motors A thick piece of Kevlar you find in a surplus yard is destined to be your robot s sub-skin, to be covered by a sheet of 304 stainless steel bonded to it All of these materials have their strengths and weaknesses
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Aluminum is probably the most popular structural material used in experimental robot construction It offers good strength, though it s certainly not as tough as steel Its best characteristics are its ability to be machined, its availability, and its light weight You might be able to go to a junkyard and ask for aluminum, and the sales person will lead you over to a pile of twisted metal Enter a metal supply house, and you ll be asked what alloy, what temper, and do you want sheet stock
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