When it comes to robots, we usually see some aluminum extrusion, laser-cut parts, maybe some 3D printed parts, and possibly a few Erector sets confabulated into a robot arm. This entry for the Hackaday Prize is anything but. It’s a robot chassis, a 3D printer, and the structural frame for any sort of moving project that’s made out of a special composite material.
[Marc]’s project for the Hackaday Prize is all about articulated mechanisms. Instead of the usual structural components, he’s using Hylite, a special material that’s basically a polypropylene core clad in a sheet of aluminum on both sides. By carefully milling away the aluminum on both sides, [Marc] is creating a living hinge that can be used to build a 3D printer, robot, or really anything else.
This really isn’t a finished project; it’s more of a technology demonstrator. That said, [Marc] has a lot of examples where he can bend these Hylite aluminum plates over on themselves, can create boxes and space frames, and has the ability to create just about any shape he wants. It’s really a highly precise means of bending aluminum with a mill, and has the added benefit of looking really, really good.
Already, [Marc] has a few interesting robots that are built around this construction technology. The first is a remote control focus for a telescope that simply connects an eyepiece to the scope. Actuation is provided pneumatically, and all reports say this example works well. The other example is a flat-pack phone stand. It’s a bit simpler than a focus mechanism, but it is a small and inexpensive way to show off the technology. Great work, and an excellent project in The Hackaday Prize.