Robot Fabrication via Layered Manufacturing

Robots deployed by the DoD and in industry increasingly demand complex electro-mechanical systems that utilize high levels of integration within small packages. In addition, the cost of these devices needs to be an order-of-magnitude lower than current levels to effectively augment today"s warfighter on the battlefield it is surely more effective to deploy ten $10K robotic arms instead of a single $100K arm to disable IEDs. Layered printing and sheet assembly processes are a promising technology that can address this need. Two-dimensional patterned sheets are typically much quicker and cheaper to produce than 3D forms. Layering offers the ability to combine different types of materials, to construct complex laminated 3D structures, and to embed a robot"s actuators, sensors, communication systems and electronic controls within a single integrated structure. We propose a new manufacturing process for producing low-cost yet complex robotic systems. The process extends two mature manufacturing technologies: Shape Deposition Manufacturing and Laminated Object Manufacturing. It features end-to-end automated manufacturing capability and does not require specialized tooling, allowing for rapid and low-cost design changes. It will enable the manufacture of low-cost electro-mechanical micro-structures integrated into durable, flexible robot links.