EnCata supported a robotics startup as an engineering contractor, developing a custom warehouse robot (400 kg load) for indoor and outdoor use — from concept to pilot-ready prototype. All IP belongs to the customer.
Industry:
Services:
TRL:
3 → 8
Project duration:
6 months
A robotics startup needed an engineering partner to bring their early-stage warehouse robot (TRL-3) to a pilot-ready state. While the customer had strong in-house expertise in embedded systems and software, they turned to EnCata for full-cycle hardware development.
We were engaged to:
Wireless battery charger design
DC motor wheel
CNC milling & lathe
Laser cutting CNC
Sheet metal bending CNC
Kinematic simulations
Welding
Video camera for MV
Lidar technology
Vacuum forming
EnCata began the project by refining the concept and conducting robot carriage/suspension simulations to ensure its stability and effectiveness in a variety of situations.
Having completed a multitude of various kinematic simulations and use-cases, EnCata’s engineers proceeded to finalize the concept while our industrial designers gave the robot a fashionable touch.
We tried to move away from the typical chunky straight lines of industrial robots and suggested a streamlined clean robot shape, while at the same time having the DFM in mind. Thus the industrial design phase left the customer with the design of the cover made with vacuum forming technology in order to reduce the robot production costs.
We worked closely with the startup team on the electrical development, BOM optimization, and components procurement. The robot implemented several essential components such as:
With the detailed prototype CAD, we proceeded to source components, design tools, and manufacture the alpha.
The robot was then first assembled as a ‘skeleton’ chassis. Components, electronics and wires were added later. The startup team took an active role in robot assembly and wiring.
The “Stripped alpha” robot prototype was produced in-house and underwent the EVT (TRL-5 tests).
Following the tests, a mold for vacuum forming was designed and manufactured. The ‘skeleton’ was upgraded with the enclosure of the DVT (design validation tests).
After the prototype tests, we finished with the DFM, updated the CADs, and produced the documentation/drawings for batch production.
The startup moved from a rough proof-of-concept to a working prototype ready for pilot production (TRL-8) — complete with DFM and custom tooling. EnCata delivered the physical robot, while the client stayed focused on what they do best: software and system integration.
Need help building your own hardware prototype? Talk to our engineers or check out our mechanical engineering services to get started.
from concept to fully functional robot prototype
the robot’s maximum load
the robot is protected from rain and water jets
