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What is Manufacturing and Assembly?
From Concept to Competition-Ready
Welcome to the Manufacturing and Assembly section. This resource is designed to guide FTC teams through the machining and assembling their . Whether you're new to robotics and looking to integrate small custom end effectors, or a more experienced ambitious team looking to build their first custom chassis, this section offers valuable insights into the machining, materials, and assembly essential for robust reliable robot construction.
Ideal Manufacturing Techniques
Overview of the best methods of making custom parts used in FTC
Which methods to apply to which parts
Tools and Equipment
Overview of common tools used in FTC robot construction
helpful tips to ensure assembly efficiency
Materials Selection
Comparison of materials like aluminum, steel, and plastics, as well as 3d printable filaments
Criteria for choosing materials based on robot requirements
Sources for procuring quality materials
Fastening and Joining Techniques
Methods for securely connecting robot components
Use of screws, nuts, bolts, and alternative fastening methods
Tips for ensuring structural integrity during matches
Assembly Best Practices
Assembly order Ideology
Alignment and calibration techniques
Strategies for modular design to facilitate easy repairs
Tools and Equipment
Materials Selection
Fastening and Joining Techniques
Assembly Best Practices
Quality Assurance
"" — Team
"" — Team
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.
Titanium is an advanced engineering material known for its exceptional strength-to-weight ratio, making it a premium choice in aerospace, defense, and high-performance applications. Titanium sheets are significantly stronger than aluminum while weighing about 45% less than steel, offering excellent mechanical performance without unnecessary weight.
For FTC teams, titanium is an interesting—though niche—option. Its standout features include:
High Strength-to-Weight Ratio: Titanium is nearly as strong as some steels but much lighter, making it useful when you need durability without adding excessive mass to your robot.
Corrosion Resistance: Titanium naturally resists rust and oxidation, making it ideal for environments with high moisture, exposure to elements, or even chemically corrosive conditions.
Temperature Resistance: Aerospace-grade titanium alloys can withstand extreme heat, which makes them ideal in contexts like high-speed motors or thermal isolation plates (though rare in FTC).
Biocompatibility: Although not relevant to FTC, titanium is used in medical devices for its compatibility with the human body—a testament to its safety and chemical stability.
Long-Term Durability: It doesn’t fatigue or wear down easily, so components made from titanium are built to last over many seasons or repurposings
Cost: Titanium is expensive—significantly more than aluminum or steel. For most FTC teams working with limited budgets, this is a major limiting factor.
Difficult to Machine: Titanium is notoriously tough on tools. It requires specialized equipment and slower cutting speeds, making it less practical for teams without access to advanced fabrication tools like CNC mills or waterjets.
Limited Availability in FTC Scale: It’s less commonly available in standard robotics formats (like extrusion profiles or pre-cut brackets), and sourcing custom titanium parts often takes more time and effort.
Weight Compared to Aluminum: While it’s lighter than steel, titanium is still heavier than aluminum, which is typically a better material when weight savings is the top priority.
Proper tolerancing is essential for ensuring parts fit correctly. If a hole is designed to be exactly 1/4” for a dowel pin and cut using a waterjet or laser cutter, the fit may be inaccurate.
Waterjets produce tapered cuts, making the hole too small, while laser cutters often cut on the line, resulting in a slightly oversized hole.
Traditional CNC machines, like mills or lathes, achieve much tighter tolerances when properly configured.
Similarly, FDM 3D printing introduces dimensional inaccuracies due to extrusion variations, thermal expansion, and layer adhesion inconsistencies. Factors like nozzle diameter, print speed, and material shrinkage can cause holes to be slightly larger or smaller than intended.
The most common 3d printing method
FDM (Fused Deposition Modeling) >
A 3D printing method in which a thermoplastic is melted and extruded through a nozzle to print an object layer by layer. This is the most common type of 3D printer because of its affordability, ease of use, and versatility.
There are two types of FDM Printer: Bedslinger and Core XY.
Bed Slinger
Core XY
Price
Generally cheaper due to lower material cost and simpler design.
Generally, more expensive due to the complexity and cost of high-quality materials.
Maintaince
The design is simpler, making them easier to build, maintain, and repair.
The assembly and maintenance are complex, requiring regular upkeep.
Print speed
Slower due to the movement of the entire bed.
Faster due to the stationary motors and lighter moving parts.
Quality
The moving bed causes more vibration, which creates lower-quality prints.
It minimizes vibration-induced errors, leading to highly accurate prints
Size of bed
As the size of the print bed increases, the issues with speed and vibration become worse.
The movement along the X- and Y-axes allows for larger prints.
Aluminum is lightweight and corrosion-resistant. It is easy to machine, stamp, weld, and drill, making it a popular choice for a wide range of applications, from parallel plates to electronics. It is very popular with FTC teams since it has one of highest strength to weight ratios for the price range. See Aluminum Alloys >
Laser cut steel is a popular choice since it's the most cost effective metal for laser cutting. It's significantly denser than aluminum which makes it less popular for whole chassis, but it's still usable for a strong end effector part. See Steel Alloys >
Stainless steel is a popular choice for a wide range of applications, its food safe, corrosion resistant, and easy to clean. Learn more about stainless steel and what sizes we can cut and form.
Titanium is a high-performance metal known for its incredible strength-to-weight ratio and corrosion resistance. It’s stronger than aluminum and lighter than steel, though far more expensive. It’s best used in applications where strength and durability are critical, and weight is a constraint. See Titanium Alloys >
Carbon fiber is a composite material that combines extremely high tensile strength with ultra-lightweight construction. While expensive and brittle under certain conditions, its strength-to-weight ratio is unmatched. Best suited for structural components where minimal weight is essential. See Carbon Fiber Options >
Filaments offer unique flexibility for rapid prototyping and functional parts. From standard PLA and PETG to advanced materials like TPU or carbon-reinforced nylon, the right filament can provide strength, elasticity, or heat resistance depending on your design.
All Types of precision subtractive machining
Computer Numerical Control (CNC) machining is a manufacturing technique that uses computer software to control the movement of machinery and tools. This technology can manage a wide variety of advanced machines, including grinders, , , and CNC routers, enabling complex three-dimensional cutting operations with just one set of instructions.
Once a CNC system is started, the programmed instructions guide the tools and equipment to perform the required operations—similar to how a robot functions.
CNC programming involves a code generator that typically assumes the machines will operate without fault, although errors can increase when cutting in multiple directions at once. The positioning of each tool is determined by a sequence of commands known as the part program.
Traditional numerical control machines received instructions via punch cards, while CNC machines use keyboards to input programs directly into a computer. These programs are stored digitally and can be written and modified by programmers. CNC systems offer greater computing power and flexibility, allowing updates or new commands to be added to existing programs through code revisions.
Additional CNC References
Screws are one of the most commonly used fasteners in FTC and are essential to structural integrity and modularity. Choosing the right screw type can affect weight, strength, ease of maintenance, and durability under vibration.
Threadlocker is a type of adhesive that’s applied to screw threads to prevent loosening due to vibration or shock. FTC robots undergo constant motion—especially in drivetrains and arms—so threadlocker is essential for keeping screws from backing out during matches.
Blue Threadlocker (Removable) This is the most commonly used threadlocker in FTC. It prevents loosening but still allows you to remove the screw later with hand tools. Ideal for drivetrain components, mounting plates, motor screws, and anywhere vibrations are common.
Red Threadlocker (Permanent) This is much stronger and usually requires heat to remove. It’s not recommended for FTC unless you're securing something you never plan to take apart (like press-fit bearings or permanent inserts).
Purple Threadlocker (Low Strength) Good for small screws (like M2 or M3) or delicate parts. Easier to remove than blue but still provides some vibration resistance.
The most common washer type. They distribute the screw’s force over a larger area, which protects softer materials like plastic or aluminum from being crushed or deformed. Also useful in slotted holes to prevent slipping.
Designed to resist loosening. They come in split-ring or star (internal/external tooth) varieties. These are less common in FTC, where blue threadlocker or nylon-insert nuts are typically preferred.
Extra-large washers that spread force across a wide surface. Useful for mounting electronics, covering oversized holes, or protecting soft materials like polycarbonate.
Non-conductive and slightly compressible. Used for isolating electronics or protecting fragile surfaces. Common in mounting sensors, batteries, or REV hubs.
Fasteners are critical in FTC manufacturing, holding together everything from chassis rails to motor mounts. Common FTC fasteners include socket head screws, hex bolts, nuts, washers, and standoffs—most using M4 threads.
Threading refers to the spiral grooves inside a hole or on the outside of a shaft that allow a fastener to grip and hold. In FTC, this is usually done by tapping holes—cutting threads into a drilled hole using a tool called a tap. Tapping allows you to secure fasteners without needing a separate nut, which saves weight and space.
Tapping Holes: Start by drilling with the correct tap drill size (e.g., #36 drill for 6-32 threads). Use a tap handle and cutting fluid if possible, turn slowly, and back off frequently to avoid breakage.
Threaded Inserts: If you’re working with 3D-printed parts, threaded inserts (heat-set or press-fit) provide durable threads that won't strip out under torque.
SLA (Stereolithography)>
A 3D printing method that uses a laser to cure layers of a liquid photopolymer resin together. This is often used to create high-quality, accurate prints with smooth surfaces and intricate details. Using an SLA 3D printing gives a versatile range of materials available.
Depending on the formulation and chemistry, some resins can be leveraged to produce pure silicone, polyurethane, or ceramic parts. Resin 3D printing also offers the broadest spectrum of biocompatible materials, opening up doors in end-use products, medical equipment, 3D printing at the point of care, and medical procedure innovation.
How Does SLA 3D Printing Work? >
SLA 3D printing uses a light source to cure liquid resin into three-dimensional objects by exposing a vat or tank of resin to a light source, which hardens it
Additive vs. Subtractive Manufacturing
Custom parts can be as simple as a battery mount to something as large as a parallel plate chassis. The key to designing successful functioning mechanisms is to balance custom and off the shelf parts.
Custom Parts can be made in many different ways. You should always design parts while keeping in mind how you will manufacture them. There are 2 different types of manufacturing techniques. Additive and Subtractive Manufacturing.
Additive Manufacturing involves adding successive layers of material to create an object.
Additive Manufacturing works by either
melting or fusing powders
curing liquid polymer materials
melting spools of composite materials
These methods are used to form final parts based off of technical sketches. Some services online even take CAD files and post process them in-house to manufacture your design.
The surface finish is not as smooth as subtractive manufacturing, and the tolerances aren’t as precise. These processes are ideal for lighter parts, material efficiencies, rapid prototyping, and small to medium-batch manufacturing.
Complex geometries, including the printing of articulating joints with additive manufacturing, are available. The geometries are more complicated, and set-up is quick and easy, with no operator required during the printing process. The most common materials used in additive manufacturing are plastics and metals. The equipment cost is less than subtractive manufacturing, and various material colors are available for most 3D printing operations.
Subtractive manufacturing removes material to create an object.
Subtractive manufacturing works by material removal by
Milling
Drilling
Grinding
Cutting
Boring
The material is typically metals or plastics, and the end product has a smooth finish with tight dimensional tolerances. A wide variety of materials are available.
Change-overs are longer, but automatic tool changers help reduce time-consuming delays. The processes can be fully automated, although an attendant may oversee two or more machines.
The equipment costs are higher and usually require additional jigs, fixtures, and tooling. It is best suited for large production with reasonably fast manufacturing time but lengthy changeovers. Material handling equipment helps both processes with material loading and removal. Geometries are not as complex as additive manufacturing processes.
5052 aluminum is a popular choice for FTC teams fabricating custom metal parts, especially with laser cutting. What sets 5052 apart from other aluminum alloys—like 6061—is its superior corrosion resistance and excellent bendability without cracking. While 6061 may be stronger in some applications, 5052 is easier to form and better suited for parts that require tight bends, curves, or precision tabs and slots.
Its high fatigue strength and moderate-to-high strength make it ideal for structural brackets, chassis panels, and load-bearing supports. Additionally, 5052 performs exceptionally well in environments where moisture or oxidation may be a concern—an advantage over more brittle or corrosion-prone alloys. For teams looking for a balance of strength, formability, and durability, 5052 is one of the most versatile and cost-effective choices available.
Density
0.098 lb/in3
0.098 lb/in3
0.098 lb/in3
Ultimate Tensile Strength
28 ksi
33 ksi
38 ksi
Yield Tensile Strength
13 ksi
28 ksi
31 ksi
Fatigue Strength
16 ksi
17 ksi
18 ksi
Shear Strength
18 ksi
20 ksi
21 ksi
6061 aluminum is one of the most widely used aluminum alloys in the world—and for good reason. It offers an excellent balance of strength, corrosion resistance, and machinability, making it ideal for structural components in FTC robots. Unlike 5052, 6061 can be heat-treated through a process called precipitation hardening, which significantly increases its strength while preserving its other valuable properties.
In FTC applications, laser-cut 6061 aluminum excels in load-bearing structures such as drivetrains, arms, and lift systems. It handles high-impact forces well and has strong fatigue resistance, making it a smart choice for parts exposed to vibration or repeated stress.
Another advantage of 6061 is its excellent weldability and compatibility with post-processing methods like anodizing, which adds a protective layer to the metal surface. While it’s less formable than 5052, 6061’s superior rigidity and versatility make it the go-to alloy for custom frames, brackets, and mounting plates.
If your team needs durable, high-performance parts that can withstand competition wear and tear, 6061 is a top-tier material to consider.
Density
0.1 lb/in3
0.1 lb/in3
0.1 lb/in3
0.1 lb/in3
0.1 lb/in3
Ultimate Tensile Strength
18 ksi
35 ksi
45 ksi
46 ksi
42 ksi
Yield Tensile Strength
8 ksi
21 ksi
40 ksi
39 ksi
40 ksi
Fatigue Strength
9 ksi
14 ksi
14 ksi
14 ksi
15 ksi
Shear Strength
12 ksi
24 ksi
30 ksi
30 ksi
25 ksi
7075 aluminum is one of the strongest aluminum alloys available and is often referred to as “aircraft grade.” Its high strength comes from its zinc and copper content, which give it mechanical properties comparable to, or even exceeding, some mild steels—especially in the T6 temper.
7075 is ideal for FTC teams building components that must handle extreme loads with minimal flex, such as arms, structural brackets, or drivetrain elements where rigidity is critical. While it doesn’t match the weldability or formability of 5052 or 6061, its strength-to-weight ratio is among the best of any aluminum alloy used in robotics.
Although its corrosion resistance and machinability are rated as average to good, 7075 is not recommended for welded parts. It can be anodized, though with less consistency than 6061. Its lack of weldability makes it more suitable for bolted or riveted assemblies rather than fully custom-welded structures.
Density
0.1 lb/in3
0.1 lb/in3
0.1 lb/in3
0.1 lb/in3
0.1 lb/in3
Ultimate Tensile Strength
max. 40 ksi(bare); max. 39 ksi(clad)
83 ksi(bare); 76 ksi (clad)
80 ksi
72.2 ksi
73.2 ksi
Yield Tensile Strength
max. 21 ksi
73 ksi(bare); 67 ksi(clad)
67 ksi
63.1 ksi
63.1 ksi
Fatigue Strength
18 ksi
23 ksi
23 ksi
20.8 ksi
21.8 ksi
Shear Strength
22 ksi
48 ksi(bare); 46 ksi(clad)
48 ksi
42.5 ksi
43.5 ksi
304 stainless steel is a strong, corrosion-resistant material commonly used in projects where long-term durability is essential. It is one of the most versatile stainless steels available, offering excellent weldability, good formability, and resistance to rust and oxidation.
For FTC teams, laser-cut 304 stainless steel can be a reliable option for components exposed to moisture, wear, or outdoor conditions. Its corrosion resistance makes it especially useful for parts that must maintain strength and appearance over time, such as structural supports or hardware on demo robots used outside the competition environment.
While it is heavier and more difficult to machine than aluminum or mild steel, 304 stainless is unmatched in durability and cleanliness. It's widely used in industries like food service, marine construction, and architecture for the same reasons.
For applications requiring even higher corrosion resistance—such as exposure to saltwater or chemicals—316 stainless steel may be a better alternative, offering enhanced protection in the harshest environments.
Water jets use high-pressure streams of water—sometimes mixed with abrasive substances—to cut hard materials like metal or granite. This method is ideal for materials that can’t withstand the heat of traditional cutting techniques. Industries such as aerospace and mining use water jets for precise, heat-free cutting that preserves the material’s properties.
These machines use a plasma torch to cut through materials, typically metals. The plasma is generated by combining compressed air with electrical arcs to produce the heat and speed required for cutting.
Used for nearly every screw in FTC. Make sure to have metric 2.5mm and 3mm depending on the hardware you use. Get T-handle or ball-end hex keys for comfort and speed. Ball end Allen Keys are a gift from heaven, they allow you to screw in screws from awkward angles, for when you didn't think the mounting through...
A good set of Phillips and flathead drivers is still useful for electronics, mounts, and quick fixes. Consider stubby or precision drivers for tight spaces. The flathead screwdriver can also double as a pry bar and as a wedge when disassembling old systems.
A few types are worth having:
Needle-nose pliers for small parts and tight spots.
Slip-joint or lineman's pliers for general gripping.
Flush cutters for zip ties and small wires.
Locking Wrench is a great tool to remove siezed, crossthreaded, or stripped fasteners
Optimizing 3d Print Machining for FTC
A 3D printer creates parts by printing a part in many layers. There are many different types of 3D printers that all use different methods for printing their layers; the most common examples are FDM, SLA, and SLS.
3D printing can be used to create parts that have complex geometry that would be impossible to create on a mill or other machine.
The most common subtractive machining in FTC
These compact and affordable cutters use a small laser diode and are best suited for cutting paper, cardboard, and thin wood. They are useful for quick prototypes and engraving designs or team information.
CO₂ machines use mirrors to direct a high-powered beam from a laser tube. These cutters are enclosed and capable of cutting wood and many plastics. They are particularly useful for making functional custom parts for FTC robots.
Fiber lasers combine multiple laser diodes into a fiber optic cable, allowing them to cut metal with high precision. These machines are typically expensive and have small working areas, making them less common among FTC teams.
Thin wood sheets are easily cut and great for prototypes or low-stress parts. Some types of wood may release fumes or present fire risks depending on their composition.
Acrylic is popular for decorative elements and lightweight guides. While easy to laser cut, it can crack under mechanical stress.
Delrin is a strong, versatile plastic that can be cut safely with proper ventilation. It is well-suited for functional robot components such as motor mounts and structural inserts.
Releases toxic gases that are harmful to both users and the machine.
Discolors and burns rather than cuts cleanly, while also emitting harmful fumes.
These plastics tend to melt instead of producing clean cuts.
Different plastics can look similar but behave differently under a laser. Avoid cutting any plastic unless you’re sure it’s safe.
Cold-rolled steel is a popular material for FTC teams who need strong, precise, and easily workable components. It starts as hot-rolled steel but undergoes additional processing at room temperature, which refines the surface finish, increases dimensional accuracy, and slightly boosts its strength and hardness.
Compared to hot-rolled steel, cold-rolled steel has cleaner edges and tighter tolerances, making it easier to use in parts that require exact fits or precise bending. These properties make it ideal for custom brackets, mounts, or other fabricated components where strength and consistency are critical.
Mild steel, a common form of cold-rolled steel, is widely used by prototyping teams and builders for its ease of machining, welding, and forming. If you're looking for a reliable material that combines strength with workability, cold-rolled carbon steel is a dependable choice for many FTC fabrication needs.
Density
0.098 lb/in3
0.098 lb/in3
0.098 lb/in3
Ultimate Tensile Strength
28 ksi
33 ksi
38 ksi
Yield Tensile Strength
13 ksi
28 ksi
31 ksi
Fatigue Strength
16 ksi
17 ksi
18 ksi
Shear Strength
18 ksi
20 ksi
21 ksi
A36-HRPO steel is a versatile and durable material used by teams that need strong structural parts with improved surface finish. It begins as standard hot-rolled steel, but undergoes a pickling process to remove surface scale, followed by an oil coating to prevent rust and improve handling.
While not as dimensionally precise as cold-rolled steel, A36-HRPO retains the strength and toughness of hot-rolled steel while being easier to work with due to its cleaner surface. This makes it well-suited for cutting, welding, and basic fabrication tasks, especially when extremely tight tolerances are not required.
For FTC teams building frames, brackets, or support structures that need strength without sacrificing manufacturability, A36-HRPO provides a reliable middle ground—offering solid mechanical performance along with easier post-processing compared to untreated hot-rolled steel.
Density
0.098 lb/in3
0.098 lb/in3
0.098 lb/in3
Ultimate Tensile Strength
28 ksi
33 ksi
38 ksi
Yield Tensile Strength
13 ksi
28 ksi
31 ksi
Fatigue Strength
16 ksi
17 ksi
18 ksi
Shear Strength
18 ksi
20 ksi
21 ksi
Carbon fiber is a high-performance composite material made from woven strands of carbon atoms, typically reinforced with resin. It belongs to a class of materials known as fiber-reinforced plastics and is formed by weaving carbon filaments into fabric, cutting it into shape, infusing it with resin, and curing it using processes like carbonization or graphitization. The result is an incredibly strong, lightweight material with one of the highest strength-to-weight ratios of any substance used in manufacturing.
Exceptional Strength-to-Weight Ratio: Carbon fiber is stronger than steel and significantly lighter, making it ideal for parts where both rigidity and low mass are essential.
High Modulus and Tensile Strength: With tensile strengths around 4,000 MPa and a modulus of ~400 GPa, it performs extremely well under load, especially in tension.
Chemical and Corrosion Resistance: Carbon fiber does not rust or degrade under most environmental conditions, making it suitable for use outdoors or in humid climates.
Thermal and Electrical Properties: It is resistant to high temperatures and, depending on the resin used, can be made electrically conductive—useful in grounding or shielding applications.
No Fatigue or Creep: Carbon fiber holds its shape over time even under constant stress, making it reliable in long-term, load-bearing designs.
High Cost: Carbon fiber is still expensive compared to aluminum or steel, limiting its use to specialized parts where weight reduction or stiffness are absolutely necessary.
Brittleness: While strong, it can be brittle—meaning it doesn’t deform before breaking. If overloaded, it may snap without warning.
Difficult to Machine: Carbon fiber is abrasive and wears down tools quickly. Cutting it typically requires carbide or diamond-coated tooling, and dust from cutting is hazardous to breathe.
Layer Direction Matters: Unlike metals, carbon fiber is anisotropic—it’s stronger in the direction of the fibers. Improperly oriented layers can lead to unexpected weak points.
Delamination Risk: Improper bonding or damage to the laminate layers can cause delamination, reducing strength and integrity.
Carbon fiber is best suited for ultra-lightweight structural parts, such as arm extensions, sensor mounts, or camera booms, especially when weight is a design constraint. While not common due to cost and machining needs, carbon fiber can offer a performance edge if used thoughtfully and fabricated with care.
CNC milling machines operate using programmed commands made up of letters and numbers, which guide tools along various paths. These programs can be based on standard G-code or custom languages developed by specific manufacturers. Basic CNC mills have three axes (X, Y, and Z), but more advanced models can include up to three additional axes for greater flexibility.
SLS (Selective Laser Sintering)>
A 3D printing method that uses a laser to fuse powdered materials, usually nylon, together to create parts. This process is known to create strong, durable parts with complex geometries.
How Does SLS 3D Printing Work? >
Printing: In this 3D printing process, a thin layer of powder is spread over a platform in the build chamber, preheated to just below its melting point. A laser then selectively heats specific areas, fusing particles to form solid parts while the surrounding powder acts as support. The platform lowers after each layer, repeating the process until the part is fully formed.
Cooling: After printing, the build chamber needs to slightly cool down inside the print enclosure and then outside the printer to ensure optimal mechanical properties and avoid warping in parts.
Post-processing: The finished parts need to be removed from the build chamber, separated, and cleaned of excess powder. The powder can be recycled and the printed parts can be further post-processed by media blasting or media tumbling.
CNC lathes rotate workpieces and use indexable tools to perform precise cuts. This technology enables high-speed, accurate machining of complex shapes that would be difficult or impossible to achieve manually. Like mills, CNC lathes typically use G-code or proprietary programming, though they usually operate on two axes—X and Z.
