Microbot Design and Manufacturing Blueprint

About the project

# Request for Complete Micro-Robot Engineering Design & Manufacturing Files **Project:** Big Hero 6-Inspired Modular Micro-Robot **Maximum Total Budget:** KRW 500,000 (approximately USD 350–370, depending on exchange rates) Hello, I am looking for an experienced robotics, mechanical, and electronics engineer to design a fully functional miniature modular robot inspired by the microbots featured in the movie *Big Hero 6*. I am not looking for a concept design or visual 3D model only. I need a complete, manufacturable engineering package that can be sent directly to PCB manufacturers and mechanical fabrication companies. My goal is to manufacture **as many fully functional robots as possible within a total budget of KRW 500,000**, including engineering design, components, manufacturing, and charging equipment. ## 1. Robot Design The robot should have: - A small, approximately spherical central body. - Two elongated wing-shaped arms extending from opposite sides. - A compact, lightweight design. - An optimized internal arrangement for the battery, PCB, motors, sensors, and mechanical components. - The smallest practical dimensions without compromising the required functionality. Please recommend the minimum feasible size based on actual component dimensions and mechanical constraints. ## 2. Required Functions **A. Independently Controlled Arms** - Two independently controlled robotic arms. - Adjustable arm angles and positioning. - Two-axis directional movement per arm, if mechanically feasible. - A target of 360-degree rotational capability, subject to mechanical limitations. - Ability to stop and hold the arms at commanded positions. - Independent motor control through software. **B. Forward and Backward Movement** - A compact internal rotating-mass or reaction-wheel-based movement mechanism. - The robot should be capable of moving or rolling forward and backward. - Please evaluate whether the proposed movement mechanism is physically feasible. - If necessary, recommend a more practical movement mechanism while preserving the intended external appearance. **C. Robot-to-Robot Connection and Separation** - Multiple robots must be capable of physically connecting. - The robots should also be capable of separating. - Connection points should be considered at the central body and arm tips. - Support for different connection configurations, including straight-line and T-shaped arrangements. - Electrically controlled docking and release mechanisms are preferred. **D. Relative Position Detection** - Robots should be able to detect or estimate the relative positions of nearby robots. - Distance and orientation estimation for docking. - Appropriate sensors and wireless communication systems. - Please explain the achievable accuracy and limitations. **E. Charging System — Mandatory Specification** The charging method must use **2-pin Pogo Pin spring-contact charging**. Requirements: - Internal rechargeable Li-Po battery. - Dedicated charging dock with Pogo Pin contacts. - Automatic electrical charging connection when the robot is placed correctly on the dock. - Integrated charging and battery protection circuitry. - Battery status monitoring. - Reverse-polarity protection or mechanically keyed contacts. - No USB-C charging port on the robot itself. The charging dock must also be included in the engineering design package, including PCB, CAD, STEP/STL, Gerber files, and manufacturing documentation. **F. Bluetooth and Computer Connectivity** - Bluetooth communication with a PC. - Wireless control of individual robots. - Independent arm movement control. - Forward and backward movement commands. - Communication with multiple robots. - Real-time transmission of sensor readings and robot status. **G. Programming and Real-Time Control** - Programmable microcontroller. - Firmware source code. - Python-based PC control interface or equivalent. - Real-time motor control. - Live sensor data monitoring. - Battery status and connection monitoring. - Documented communication protocol. - Ability to send commands to individual robots. ## 3. Required Engineering Deliverables **PCB and Electronics** - Complete circuit schematic. - Editable PCB design files. - Gerber and drill files. - Bill of Materials (BOM). - Pick-and-place files. - PCB assembly documentation. - Battery charging and protection circuits. - Motor driver and wireless communication circuitry. **Mechanical Engineering and CAD** - Complete parametric 3D CAD model. - Editable native CAD source files. - STEP and STL files. - Individual mechanical part drawings. - Manufacturing tolerances and dimensions. - Complete assembly and exploded views. - Arm joint mechanisms. - Movement mechanism. - Robot docking and separation mechanism. - Mechanical interference and clearance analysis. **Component Procurement** Please provide a complete component list containing: - Exact manufacturer part numbers. - Supplier purchase links. - Quantity per robot. - Individual and total component costs. - Physical dimensions and relevant specifications. - Current stock availability and expected lead times. - Suitable alternative parts in case of shortages. Please prioritize components that are readily available and not discontinued. **Software** - Complete microcontroller firmware. - PC control software. - Bluetooth communication implementation. - Real-time control and monitoring functionality. - Source code and installation instructions. ## 4. Manufacturing and Engineering Validation All deliverables must be suitable for real-world manufacturing rather than visualization alone. Please evaluate: - PCB manufacturability and assembly. - Internal component placement and clearances. - Motor torque and power requirements. - Battery capacity and estimated operating time. - Joint movement limitations. - Physical feasibility of the rolling mechanism. - Docking mechanism feasibility. - Expected manufacturing cost. - Mechanical and electrical integration. Please clearly distinguish between simulated or analytically validated features and features that have been physically tested. ## 5. Budget Optimization and Maximum Production Quantity **The absolute total budget limit is KRW 500,000.** This budget must include: - Engineering and design fees. - PCB fabrication and assembly. - Electronic components. - Mechanical manufacturing. - Charging dock. - Other essential manufacturing expenses. My priority is to produce **the maximum possible number of fully functional, identical robots within this budget**. Please: 1. Minimize the manufacturing cost per robot without removing essential functions. 2. Use standardized PCB and mechanical designs suitable for multiple units. 3. Consider PCB panelization, bulk component purchasing, and economical fabrication methods. 4. Calculate the actual estimated manufacturing cost per robot. 5. Provide cost comparisons for manufacturing 1, 3, 5, and 10 robots. 6. Calculate the maximum number of robots that can be manufactured within the total budget. 7. Ensure all robots can communicate and physically connect with one another. 8. Include the charging dock and engineering fees in the total budget. If the full requirements cannot realistically be achieved within the budget, please explain the technical limitations and provide a cost breakdown before proposing any changes. **Please do not remove or downgrade mandatory features without my approval.** ## 6. Final Delivery Requirements The final package should contain all editable design files, manufacturing files, firmware, software, BOM, assembly instructions, and technical documentation. The files should be suitable for submission to PCB fabrication and assembly services and mechanical manufacturing companies without requiring major redesign. I would also like ownership and modification rights to the final custom design deliverables, subject to agreement. ## 7. Questions Before Starting Please let me know: 1. Can you realistically design this robot with the requested functions? 2. What is the smallest practical robot size? 3. How much would the engineering work cost? 4. What is the estimated manufacturing cost per robot? 5. How many robots could be manufactured within KRW 500,000, including all expenses? 6. How long would the design process take? 7. Which manufacturing-ready files will you deliver? 8. Will design corrections be included if the manufacturer identifies fabrication issues? I am looking for a practical, cost-optimized, fully manufacturable design rather than a conceptual model. Thank you. I look forward to discussing the feasibility, timeline, and quotation.

Skills required