Assembly Order
Last updated
Last updated
The way you assemble your robot can make or break both the quality of your build and how long it takes to troubleshoot and iterate. A well-thought-out assembly sequence ensures that subsystems are easy to service, mechanisms align as expected, and you're not forced to disassemble the entire robot just to tighten one bolt. Taking the time to plan and build in the right order will save your team many hours down the line.
The first major step in assembly should always be the drivetrain and base frame. This is the structural backbone of the robot, so it must be perfectly square, stable, and dimensionally accurate. Tolerances matter—leave a small amount of play (typically 0.2–0.5 mm for bolt-clearance holes) to allow for easy part insertion, especially with laser-cut metal or CNC parts. Tight tolerances may look clean in CAD, but they often lead to binding or difficulty in assembling real-world parts.
Once your base is solid, the next step should be mounting major motion components like motors, gearboxes, and drive assemblies. These parts are often hard to reach once upper mechanisms are installed. Get your wheels spinning freely, your axles supported with proper bearing mounts, and ensure there’s no misalignment before continuing.
From here, build upwards by attaching key mechanisms in a bottom-up, inside-out fashion. For example, install inner lifts or center pivots before outer intakes or side-mounted arms. Doing this makes everything accessible and reduces the chance you’ll need to undo progress to add a screw. If your robot has vertical stacking—like an arm above an intake, or a turret above a lift—always mount the lower or inner mechanism first. This order also allows you to independently test mechanisms during assembly and fix any issues while they’re still easy to reach.
It’s also wise to design and assemble your robot with modularity in mind. Subsystems like arms, intakes, or depositors should be detachable with only a few screws or nuts, allowing for quick swaps or repairs between matches. If every part is bolted directly to the chassis with no separation, your team will struggle to maintain the robot under pressure. Use standoffs, slots, and clean mounting planes so that each mechanism is its own self-contained unit.
ADD THESEUS MODULAR PARTS HERE
During assembly, take care to avoid stacking tolerances across multiple parts. Even a 0.5 mm mismatch per plate can lead to severe alignment issues when stacked across five components. Add shims or slots when needed to absorb this error, and always test-fit as you go. A part that looks right in CAD may not account for laser kerf, 3D print warping, or material inconsistencies.
Finally, keep an eye on serviceability. If you can’t reach a screw without a 6-inch hex driver or disassembling a gearbox, your assembly order—or your design—needs revisiting. The best builds make sense not only in competition but also in the pits, when you need to repair or replace parts quickly. Always assemble as if you’ll need to disassemble.
By building from the base up, mounting mechanisms in an order that prioritizes accessibility, and thinking modularly, your FTC robot will not only come together more smoothly but stay reliable throughout the season.
