Making R2-D2

The aluminum dome was purchased as 2 partly laser-cut pieces of aluminum (one inside the other for depth). I cut the extra parts I wanted removed, and bolted the pieces together, then added electronics and assorted greebles (R2D2 parts) that I 3D printed. The designs for the body and legs are based largely on the Michael Baddeley v2 design files, but with lots of modifications:

  • Logics using flashing LED name badges
  • 3D Printed Holos from a Vickers scan
  • 3D Printed bridge reinforcement
  • 3D-Printed-teeth on metal-hub gear
  • 3D Printed smaller dome motor mount
  • 3D Printed nut trap plate for shoulders
  • 3D Printed tool rack for rear door
  • Buck converter speed booster
  • Aluminum direct drive motor mounts
  • Aluminum dome made by Granite Earth
  • Radar Eye made from a candy container
  • 3D Printed PSI diffusors and LED flasher holders
  • 3D printed magnetic Servo Savers
  • Baddley V3 Charge Port added
  • 3D Printed Speaker & Amp mount
  • Octoport moved to ROTJ configuration
  • Steel bracket & 3D Printed Omni-Wheels
  • Solder wick & plastic tubing for hoses

The electronics system was created by interconnecting various modules: an 8 channel PWM radio control, 1 channel radio control relay, 12 channel radio control relay, Syren and Sabre motor controllers, MP3 trigger board, Amp, power controller & thermal circuit breakers. It has two power systems, lithium (for light weight) and sealed lead-acid (in case of a location with a lithium ban) and a buck converter to upscale both to a common drive voltage for higher speeds. R2-D2 has a working gripper arm and utility arms. Finally, R2D2 was weather with 3 different colours of paint and some baking soda & steam weathering of the copper hoses.

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