I started with a problematic robotic prototype and, working with PhD colleagues, identified major issues like underperforming motors, a chassis failing environmental tests, and unreliable leg positioning. I redesigned the chassis to be waterproof, rugged and silent, and recommended better equipment available in the market. This resulted in a high-performance robot now in use. Throughout the design, I constantly collaborated with PCB designers to ensure well thought integration of all components, creating a timeless configuration.

In the 3D design phase, I utilized my deep knowledge of material properties to achieve remarkable improvements. I added soundproofing, enhanced heat dissipation, integrated night vision, and optimized antenna positioning. Despite reinforcing the legs to withstand falls from up to 2 meters and streamlining the user interface for faster and safer battery changes, I not only maintained but actually elevated the overall performance of the platform. These upgrades were achieved without compromising weight which is not an easy feat, proving that I successfully enhanced the robot’s capabilities and efficiency across the board.

During the manufacturing phase, I introduced the company to three popular and well-known manufacturing techniques, providing initial examples that significantly enhanced our approach. Which led to a notable reduction in production time and costs while increasing the versatility of our product development. I also updated the manufacturing documents to improve communication between the company, designers, and manufacturers. Additionally, I created detailed yet streamlined assembly documents, ensuring future technicians, engineers and executives could thoroughly understand and execute the design.

This project demonstrated a comprehensive approach to robotic design and manufacturing, addressing key challenges and implementing advanced solutions. By overhauling the prototype, integrating cutting-edge techniques, and improving documentation, I delivered a high-performance, cost-effective solution that set a new standard for future projects. The results not only enhanced the robot's capabilities but also streamlined processes for ongoing and future development.