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STRUCTURAL MATERIALS
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TABLE 3-1 MATERIAL Wood Plywood Steel Aluminum G10FR4 Particle Board Cardboard Foamboard Plexiglas Polystyrene
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Robot Structural Materials Comparison Chart AVAILABILITY Excellent Excellent Good Good Fair Excellent Excellent Good Good Good COST Good Fair Good Fair Poor Good Excellent Good Good Fair STRENGTH Poor Excellent Excellent Excellent Good Excellent Fair Good Poor Fair Fair Fair Poor Fair CUTTING Poor Excellent Fair Poor Fair Fair Good Poor Fair Good Excellent Excellent Poor Fair Good Excellent STABILITY Poor Excellent Good Excellent Excellent Excellent Excellent Poor Fair Poor Poor Good Good VIBRATION Good Excellent Good Fair Excellent Poor Poor Excellent Poor Poor
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the material s dimensions change over time or temperature is stability, and vibration lists how well a material will stand up to the vibration of working on a robot.
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Paper probably does not seem like a very likely material to use in the development of robots, but it, along with related products, are often overlooked as materials that are easy to work with and allow fast results. There are a variety of different paper products to choose from and by spending some time in an artists supply store, you will probably discover some products that you never thought existed. There are a number of different papers, cardboards, foam-backed boards, and so on that could be used as part of a robot s structure. Like anything, it just takes a bit of imagination. You may not have thought of this, but paper and cardboard are excellent materials for building prototypes of your robots or different parts of them. Even if you have the correct tools for cutting and shaping wood and metal, you can still cut sample parts from a piece of cardboard much faster to ensure proper fit and clearances to other parts. Many people start by building a prototype structure out of the material they are going to use in the robot with the idea that they can cut, saw, drill, or sand the piece into shape as necessary. Experimenting on the actual robot material is a lot more work (and potentially more
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expensive) than first cutting out a piece of cardboard or foam-backed paper and trimming it (using either scissors or a hobby knife) into the correct shape. Once the cardboard has been trimmed to the correct shape, it can be pulled out and measured to find the exact changes, which are then transferred to the drawings used for cutting the real material into shape. Along with scissors and a hobby knife, you might want to also invest in a cutting board (which can be found at the artists supply store) designed to be impervious to the sharp edge of the knife and some white glue. An obvious way to ensure that the cardboard or foambacked paper is at the correct dimensions is to glue a printout of the piece that is going to be used in the robot. There is one area that can be a concern if paper products are used for prototyping robot structures and that is the thickness of the material. Only in very rare cases will the cardboard or whatever material you are using for prototyping be the same thickness as the final material. This isn t a major concern because with a little bit of thinking ahead there will be no problem, but it is something to keep in the back of your mind.
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There are many different wood products to choose from for use in a robot s structure and each one has its own characteristics that affect its suitability in different areas of the robot s structure. The biggest advantages of wood are its ability to be worked using inexpensive hand tools and its fairly low cost. Even for more exotic hardwoods, which can be quite difficult to work and are relatively expensive, you will find that they can be shaped with patience along with care, and even if the piece ends up being ruined replacement pieces can be purchased for just a few dollars. When using woods as structural pieces in your robot, you are advised to use the hardest woods that you can find (such as maple, cherry, and oak). Very hard woods will obviously handle the greatest loads and, more importantly, will resist splitting at bolt attachment points. Soft woods like spruce and balsa should be avoided for obvious reasons. When fastening pieces of wood to other pieces, nuts and bolts should be used (and not screws which cut their own threads) to minimize the chance that the wood will be damaged and split or the holes will open up due to vibration. Along with solid pieces of wood, there are a number of composite products that you might want to consider. The most commonly used composite wood product is plywood (Fig. 3-1), which consists of several sheets of wood glued together in such a way that its strength is maximized. Plywood is often manufactured from softer woods (such as spruce) with the final product being much stronger than the sum of its parts. Home construction plywoods should be avoided; instead you should look at aircraft quality plywood (which can be found in small sheets at hobby stores). Aircraft quality plywood is manufactured from better quality woods to more exacting quality levels to ensure that they can withstand large forces and vibration at a fairly light weight just what is desired in a robot. Other composite wood products include chipboard and particle board in which varying sizes of wood cuttings are glued together to form a sheet of material. These materials tend to be very heavy and do not have very good structural qualities in terms of mechanical
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