You need to create custom actuators for your robotics project. How can you make sure they’re the best?

2 Design the mechanism

The next step to create custom actuators is to design the mechanism that will convert the input energy into the output motion. Depending on the type of actuator you chose, you might need different components, such as gears, belts, pulleys, screws, levers, springs, or magnets. You should also consider the kinematics and dynamics of your mechanism, such as the position, velocity, acceleration, force, torque, and power of your actuator. You can use software tools, such as CAD (computer-aided design) or FEA (finite element analysis), to model and simulate your mechanism and optimize its performance.

3 Select the materials

The third step to create custom actuators is to select the materials that will make up your mechanism. The materials you choose will affect the strength, weight, durability, and cost of your actuator. You should also consider the environmental conditions that your actuator will operate in, such as the temperature, humidity, corrosion, or vibration. Some common materials for actuators are metals, such as steel, aluminum, or brass, plastics, such as ABS (acrylonitrile butadiene styrene) or PLA (polylactic acid), or composites, such as carbon fiber or fiberglass. You can use online databases, such as MatWeb or MakeItFrom, to compare the properties and prices of different materials.

4 Fabricate the parts

The fourth step to create custom actuators is to fabricate the parts that will form your mechanism. Depending on the complexity and precision of your parts, you might need different fabrication methods, such as machining, molding, casting, or 3D printing. You should also consider the tools and equipment that you have access to, such as a lathe, a mill, a drill press, a CNC (computer numerical control) machine, or a 3D printer. You can use online services, such as Shapeways or Xometry, to outsource your fabrication if you don't have the resources or skills to do it yourself.

5 Assemble the components

The fifth step to create custom actuators is to assemble the components that you fabricated into a functional mechanism. You might need different assembly methods, such as fastening, welding, gluing, or soldering, depending on the materials and shapes of your components. You should also consider the alignment and clearance of your components, as well as the lubrication and maintenance of your mechanism. You can use online guides, such as Instructables or Hackaday, to get inspiration and tips for your assembly process.

6 Test and refine

The final step to create custom actuators is to test and refine your mechanism and make sure it works as expected. You might need different testing methods, such as measuring, calibrating, debugging, or benchmarking, depending on the type and performance of your actuator. You should also consider the feedback and control of your actuator, as well as the integration and compatibility with your robot. You can use software tools, such as Arduino or ROS (robot operating system), to program and communicate with your actuator and monitor its behavior. You can also use online forums, such as Stack Overflow or Reddit, to get help and advice from other robotics enthusiasts.