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STRUCTURAL MATERIALS
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FIGURE 3-1 Plywood is manufactured from thin sheets of wood called veneer glued together with their grains pointing in alternating directions to maximize the strength of the final piece of wood.
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strength and vibration resistance. Some of the better quality particle boards may be suitable for use in large robots, but for the most part they should be avoided.
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3.3 Plastics
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There are probably more different types of plastics than of paper products, woods, and metals combined. Determining the correct type of plastic for a specific application can be a very intensive task and take an unreasonably long period of time. Instead, you more likely will pick up a piece of plastic that you either find as raw material for sale or want to modify an existing product which for all intents and purposes is the level of consideration required for most hobby robot projects. There are three major types of plastics you can consider: Thermoset plastics are hard and have a tightly meshed molecular structure. They generally cure or harden in a mold using chemicals, and during the process they tend to put out a lot of heat. Thermoset plastics can only be shaped by machining as heating them up will destroy the molecular bonds and render the material useless. Thermosets are used in hard plastic toys, appliances, and other products requiring structural strength. You have most likely encountered elastomer plastics and thought that they were rubber bands. Elastomers have a similar molecular structure to thermosets, but they are much
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3.4 METAL STOCK
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looser, resulting in elastic characteristics. Like thermosets, elastomers cannot be shaped by heating. Thermoplastics tend to be manufactured as sheets of material of varying thicknesses for a variety of different purposes. At one thickness extreme they are used for plastic bags; and at the other, Plexiglas. Thermoplastics have a long, linear molecular structure that allows them to change shape when heated (unlike the other two types of plastics). Along with Plexiglas, which could be used as a structural material for a robot, sheets of polystyrene (the same material used to make plastic toys and models) can be formed into covers and bodies for a robot using heat and a vacuum-forming process.
3.4 Metal Stock
Metal stock is available from a variety of sources. Your local home improvement store is the best place to start. However, some stock may only be available at specialized metal distributors or specialized product outlets, like hobby stores. Look around in different stores and in the Yellow Pages and you re sure to find what you need.
3.4.1 EXTRUDED ALUMINUM
Extruded stock is made by pushing molten metal out of a shaped orifice. As the metal exits it cools, retaining the exact shape of the orifice. Extruded aluminum stock is readily available at most hardware and home improvement stores. It generally comes in 12-ft sections, but many hardware stores will let you buy cut pieces if you don t need all 12 ft. Even if you have to buy the full 12-ft piece, most hardware stores will cut the pieces to length, saving you the trouble of doing it yourself. Extruded aluminum is available in more than two dozen common styles, from thin bars to pipes to square posts. Although you can use any of it as you see fit, the following standard sizes may prove to be particularly beneficial in your robot-building endeavors:
1-by-1-by-1 16-in angle stock 57 64-by-9 16-by-1 16-in channel stock 41 64-by-1 2-by-1 16-in channel stock Bar stock, in widths from 1 to 3 in and thicknesses of 1 16 to 1 4 in
3.4.2 SHELVING STANDARDS
You ve no doubt seen those shelving products where you nail two U-shaped metal rails on the wall and then attach brackets and shelves to them. The rails are referred to as standards, and they are well suited to be girders in robot frames. The standards come in either aluminum or steel and measure 41 64 by 1 2 by 1 16 in. The steel stock is cheaper but considerably heavier, a disadvantage you will want to carefully consider. Limit its use to structural points in your robot that need extra strength. Another disadvantage of using shelving standards instead of extruded aluminum is all the holes and slots you ll find on the standards. The
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