Why the Initial Concepts of Humanoid Robots often Differ Drastically from the Final Products

Anyone who follows robotics will notice a recurring theme: the initial concepts of humanoid robots often differ drastically from the final product. This phenomenon isn’t unique to robotics and exists in other fields, but it is particularly pronounced in robotics design. In the past, there was little need for early high-fidelity concepts in robotics. However, with the growing commercialization of robots, creating an early industrial design concept that is eye-catching has become increasingly important. As a result, we are often presented with sleek, hyper-capable, and overly ambitious concepts that ultimately give way to far more limited realities. Why does this happen?

One Thing I’ve Learned After Years of Working with Robotics Teams

Things change, and they change all the time, until the last moments. This might come as a surprise, but today, it’s an inherent nature of robotic projects. However, the initial concepts are often not flexible enough to adapt to these changes.

A concept should be a solution that can be applied to the product, no matter the changes. A concept design should be like a repeatable template of forms, materials, colors, and interaction that, even if one of the limbs is removed, can still be applied to the rest.

The Complexity of Robotics Systems

One key reason lies in the inherent complexity and limitations of robotics systems. Humanoid robots are an intersection of advanced engineering, software, hardware, and design. Each of these domains has its constraints, and achieving harmony between them is no small feat. While industrial designers might dream of creating fluid, organic shapes with seamless materials, engineers are grappling with the challenges of wiring, actuators, sensors, and cooling systems. These practical constraints often force compromises that take the final product further away from its initial concept.

As I previously discussed in my article "Why Humanoid Robots Look the Way They Do: Understanding Rodney Brooks's First Law of Robotics," a robot's exterior should accurately reflect its capabilities. However, achieving this balance is challenging due to robotics' multifaceted nature. What matters here, is a close collaboration between the design team, management, and technical team. In projects with high level of complexity, it is common for designers and engineers to work in isolation. However, they had better dive into the complexity and interactions and embrace them.

The Role of Industrial Designers in Bridging the Gap

This disconnect could be minimized if industrial designers had a deeper knowledge of robotics systems. By understanding the technical limitations and requirements, designers could create concepts that are much closer to the final product. This approach requires a holistic view of the project, where design is not just about aesthetics but also about functionality, manufacturability, and maintenance.

This notion aligns with the principles I outlined in "Applying the Double Diamond Design Thinking Method in the Humanoid Robot Industrial Design Process," where I emphasized the importance of integrating design thinking frameworks to bridge conceptualization and realization.

System Thinking Meets Design Thinking

Designers should cultivate a sense of system thinking combined with design thinking. System thinking involves considering all stakeholders, disciplines, components, and their interrelationships as integral design elements. This holistic perspective ensures that the design process accounts for the entire ecosystem of the robot, leading to more realistic and viable concepts. By combining this with design thinking, which emphasizes user-centric solutions, designers can bridge the gap between visionary concepts and practical realities.

For example:

• Elastic Materials in Degrees of Freedom Areas: While it’s tempting to use elastic materials for areas requiring flexibility, such as joints, this concept is challenging to implement in production. Elastic materials, if not implemented thoughtfully, can strain actuators, complicate sealing, and degrade over time. (it was discussed thoroughly in this article)
• Wiring and Cable Harnesses: Concept designs often ignore the space needed for wiring and cable harnesses. In reality, these are critical components that significantly impact the robot’s appearance and functionality (I would love someone to write about this).
• Face Design and Sensors: A common design trope is using a sleek black screen for the robot’s face without considering the placement and visibility of cameras and sensors or how to integrate interactive elements like eyes or displays.

Design for Excellence (DFX)

Another essential principle is Design for Excellence (DFX). From the earliest stages of concept design, designers should consider factors such as maintenance, accessibility, manufacturability, and scalability. These considerations not only ensure that the design can transition smoothly into production but also improve the robot’s overall usability and longevity.

If these elements are overlooked, the concept risks being nothing more than a marketing stunt. This can lead to a final product that fails to meet customer expectations, tarnishing both the product and the brand.

Collaboration and Cross-Disciplinary Understanding

The design and production of humanoid robots demand close collaboration among all team members, including designers, engineers, and software developers. Team members must have a solid understanding of each other’s disciplines to anticipate and address potential challenges early. Furthermore, designers should stay involved throughout the development process rather than exiting after the concept phase. This continuity ensures that the design intent is preserved and adapted as necessary.

As highlighted in "Positioning Industrial Design Stages Within the Engineering V Model for a Typical Robotic Project," a unified approach ensures that design intent is preserved throughout development, leading to more realistic and functional outcomes.

Practices to Improve Concept Realization

To bridge the gap between concept and reality, we need to adopt certain practices:

1. Early Integration of Constraints: Designers should work closely with engineers from the outset to incorporate technical and manufacturing constraints into their concepts.
2. Iterative Prototyping: Rapid prototyping and testing allow teams to identify and resolve issues early, making it easier to align the concept with the final product.
3. Design for Maintenance: Considering aspects like cable routing, material wear, and access for repairs can result in more realistic designs.
4. Focus on Scalability: Concepts should factor in cost-effective manufacturing processes and material availability.

Closing Thoughts

The journey from concept to production is inherently challenging, especially in robotics. However, by fostering a collaborative culture, equipping designers with the necessary technical knowledge, and addressing practical constraints from the start, we can create humanoid robots that not only look good on paper but also perform effectively in the real world. By aligning visionary design with real-world feasibility, we can bridge the gap and build robots that live up to their initial promise.

Image Disclaimer: The images above, belonging to Figure AI, Tesla, Kind Humanoid and Apptronik (from top-left to bottom-right), are included for educational purposes. The content of the article does not address any specific robot.