Humanoid Robot project

We have designed a humanoid robot “ADAM” for educational purposes. The Robot is paired with proprietary VR software that enables motion control. Robot is now introduced for robotics and programming classes in schools and universties.

Industry:
Consumer

3→8

Project duration:

6 months

We have designed a humanoid robot "ADAM" for educational purposes. The robot is paired with proprietary VR software that enables motion control.  We have developed the product from 1)  refining the concept and making a new industrial design, to 2)  DFM, to 3) tooling design and manufacturing. The robot is now being used for robotics and programming classes in schools and universities.

BACKGROUND

A robotics startup dealing with educational robotic platform came to EnCata with a POC (proof-of-concept prototype) of a new humanoid robot. The TRL-4 robot prototype was already paired with the startup's proprietary educational software platform via it’s electronics.

The challenge was to make the robot look nicer, friendlier and more futuristic, while bringing both the BOM and manufacturing cost down.


WORK

EnCata’s team of design engineers started to modify the concept with newer components and electronics. Eventually, several variants of the industrial design were suggested, reflecting the preliminary robot composition and dimensions.

In order to  both reduce robot mass-production costs and increase its reliability, we suggested using a whole metal frame made almost entirely from sheet metal with  robot covers made from vacuum-formed plastic. These DFM decisions lead to a 150% decrease in production costs.

While the startup concentrated on software development, EnCata worked with their electrical layouts and preliminary BOM for electronic components. EnCata took this BOM for further refinement and optimization, followed by component procurement and robot prototyping and assembly.

RESULTS

Overall, EnCata moved this project from TRL-3 to TRL-8, at which stage the startup had a working prototype with a set of drawings, documentation and tooling for mass-production.

Here is a brief list of activities EnCata engaged on this project:

  • Concept refinement
  • Design engineering with DFM
  • Industrial design
  • Electronics and BOM optimisation
  • Tooling manufacturing
  • Industrial prototyping

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