The Hardware
Tank tracks
My first step was to design the tracks for WALL-E. Since WALL-E has a triangular shaped tracks, I attempted to position the 3 lego wheels together and fit the rubber treads for the left and right side. From there, I estimated a fixed position where the 3 wheels would be and laser cut acrylic to hold them together. The acrylic acts as a supporting frame for the positioned wheel rims. This step took a few tries to get my rubber track drive treads fit well together without it being too tight or too loose.
Animated WALL-E has a treads with changeable shapes using tensioner and lift system
While finalising my acrylic design, I also realised that it would be better if i trim the lego wheels to be narrower in width. This is so that the wheels in between looks flushed. So i sawed them on each sides. I use a total of 6 wheel rims. I also attached some washers so there could be less friction when the wheels are rotating.
Trimmed lego wheels (only 1 side)
Super glued washer both sides
I later messed up some of the given wheels. So I 3d printed my own. The 3D printed wheels are flushed as well and feature a hexagon hole for this thing to act as my axle. I printed 2 pieces and both are placed for the top position of the triangle, which will then connect straight to my continuous servo.
The thing
Body
The rest of WALL-E’s body stucture are based on chillibasket’s WALL-E replica on thingiverse. The dimension and designs are life-sized so I went to scale it down to 60% of it’s original file. To do this, I downloaded the STEP files on thingiverse and modify accordingly on Fusion 360. Most of the modification is to delete unwanted features, re-size the screw holes and group parts in pne print.
Bottom
- Custom part to link bottom to tracks
Front
- Resize the battery level detection area to put in led bar strip. (Not implemented at the end, used to arrange wires)
- Nothing
Back
- Cut out space to hold battery.
- Note: Still not enough space.
Sides, right & left
- I checked the alignment by importing other components. Made sure it all fits together and modified accordingly
- Includes servo bracket, arm hinge, motor, body-bottom, acrylic frame and linkage.
- Added holes for motor and screws.
- Reposition engraved area for force-fitted servo arm brackets
Top
- Created an on/off switch area
- Should hv check the screw hole position that connects to arm bracket
- Redesigned to 3 button holes. Idea was to add in sounds when button pressed. Not implemented.
- In final design, I change a different on/off switch model. So I drilled another hole to fit that.
Arms
3dp_arm.stl
3dp_fingers.stl
3dp_arm-hingeinner.stl
3dp_arm-hingeouter.stl
3dp_arm-hingeaxle.stl
3dp_hand-bracket.stl
3dp_hand-axle.stl
- Joined barrel and piston part. Added screw hole to minimise axle movement.
- Arm hinge outer extrude. longer.
- Arm hinge inner not scaled down to fit arm servo.
- Arm bracket for servo, not scaled down.
Neck
3dp_neck-top.stl
3dp_neck-bottomleft.stl
3dp_neck-bottomright.stl
3dp_neck-bottomaxle.stl
- Not implementing motorised neck movement since when scaled down, servo does not fit.
- So, joined the neck top parts together as one.
- Neck Bottom left and right are glued after inserting axle
Eyes
3dp_head-axle.stl
3dp_head-centre.stl
3dp_eye-middleright.stl
3dp_eye-middleleft.stl
3dp_eye-frontright.stl
3dp_eye-frontleft.stl