ROBOT COMBAT IS INHERENTLY DANGEROUS. THIS WEBSITE IS NOT A SUBSTITUTE FOR EDUCATION.
ALWAYS WEAR PROPER EYE PROTECTION AND SAFETY GEAR.
DON’T OPERATE TOOLS YOU HAVEN’T BEEN TRAINED ON.
Combat Robot Basics
Welcome! to our comprehensive guide on combat robotics, designed especially for beginners who are eager to delve into the thrilling world of robotic combat!!! Whether you’re a newcomer with little to no knowledge or someone looking to refine their understanding, you’ve come to the right place! With over two decades of hands-on experience in combat robotics, I, Bunny, alongside my collaborator Tori, who brings eight years of expertise to the table, have compiled this resource to provide you with a solid foundation. Combat robotics is a sport where you can swiftly grasp the basics and start your journey. However, to truly excel and stand among the best, dedication, time, and effort are essential. Our guide offers an invaluable starting point, offering insights collected from years of hard-earned experience. While our resource serves as an excellent introduction, the path to mastery often involves delving into more detailed sources, learning from other skilled builders, and gaining practical wisdom through participation in competitions. So, buckle up and get ready to explore the exciting scene of combat robotics with us! Ready, set, fight!!!
For detailed combat information, guidelines, and rules, visit sparc.tools online.
1. Learn the Weight Classes
Fairyweight / Fleaweight (150g)
150g weight limit!
Commonly referred to as Fairies! Part of the “Insect” weight-class.
Fairyweight robots are great for beginners, as they are small, cheap/easy to fix, and require minimum investment. You can easily download free designs online and 3D print them. To learn more about legal materials for this weight-class check out sparc.tools. Their affordability and ease of repair make them popular among beginners. While customization options are more limited due to the weight restriction, Fairyweights allow builders to experiment with various weapon configurations, enhancing their skills.
For detailed combat rules, visit sparc.tools online.
Antweight (1lb)
1lb weight limit!
Commonly referred to as Ants! Part of the “Insect” weight-class.
Antweights, weighing 1 pound (0.45 kg) or less, are the smallest combat robots. Due to their size, they demand precise engineering, agility, and strategy. Antweights often showcase innovative designs and unique weaponry, making them a popular choice for hobbyists and newcomers to robot combat.
Unlike Plants, Ants are not required to be entirely made from plastic.
However, like Plants and Fairies, Ants are small, easy to build & repair, and affordable.
For detailed combat rules, visit sparc.tools online.
Plastic Antweight/PLAnts (1lb)
1lb weight limit!
Commonly referred to as PLants! Plastic ants are really awesome! Part of the “Insect” weight-class.
A subcategory of Antweights, Plants are specifically crafted from plastic parts, offering a budget-friendly entry point into the world of combat robotics. These robots emphasize creativity within material constraints and often serve as a stepping stone for builders before they venture into heavier weight classes.
Like Fairies, these robots are small and require minimum investment. However, unlike Fairies, PLants are required to be entirely built from plastic parts (aside from electronics, motors, and fasteners). Easy 3D printing, low damage, and high fixability, make them very affordable compared to other weight-classes.
For detailed combat rules, visit sparc.tools online.
Beetleweight (3lb)
3lb weight limit!
Commonly referred to as Beetles! Part of the “Insect” weight-class.
Weighing up to 3 pounds (1.36 kg), Beetleweights offer a more robust platform for creativity and innovation. Builders have greater freedom in design, enabling the incorporation of advanced weapons, durable armor, and sophisticated control systems. Beetleweights often feature a mix of strategy and resilience, making matches in this class highly engaging.
One of the most popular and competitive weight-classes with lots of parts available over many websites.
Beetles are larger than the other insect weight-classes, as well as a larger investment of both time and money. Beetles are super competitive, highly destructive, and tons of fun!
For detailed combat rules, visit sparc.tools online.
Hobbyweight (12lbs)
12lb weight limit!
Commonly referred to as Hobbies!
A less popular, but very fun weight class! With a weight limit of up to 12 pounds (5.44 kg), Hobbyweights provide builders with more room for complex designs and formidable weaponry. These robots often feature a wide range of specialized weapons, such as powerful spinners, flippers, and gripping mechanisms. Hobbyweight competitions showcase a diverse array of strategies and technical expertise.
Hobbyweight bots are the smallest non-insect bots. They are much larger than the insect weight classes, allowing for more creativity in robot design.
They are also more of an investment, and worth building when you are more familiar with combat robotics in the lower weight-classes.
For detailed combat rules, visit sparc.tools online.
Featherweight (30lb)
30lb weight limit!
Commonly referred to as Feathers!
A more expensive, but fun weight class with lots of available parts. Featherweights, weighing up to 30 pounds (13.61 kg), are more powerful and versatile, allowing for intricate designs and formidable weapons. These robots often incorporate advanced materials, intricate engineering, and sophisticated control systems. Featherweight competitions demand a balance between offense, defense, and strategic maneuvering.
This weight-class is used by many BattleBots builders to test new robot designs before building 250lb heavyweight battlebots.
For detailed combat rules, visit sparc.tools online.
Lightweight (60lb)
60lb weight limit!
Commonly referred to as Lights!
A less popular weight class that competes at Robogames. Lightweights, with a weight limit of up to 60 pounds (27.22 kg). These robots boast a mix of power, speed, and durability. Lightweight competitions feature intense battles, with robots equipped with diverse weaponry, advanced electronics, and innovative defensive strategies, making them a favorite among enthusiasts.
(Robogames is an annual event and competition for various combat robot weight classes, hosted in Northern California.)
For detailed combat rules, visit sparc.tools online.
Middleweight (120lb)
120lb weight limit!
Commonly referred to as Middles!
Middleweights, weighing up to 120 pounds (54.43 kg), represent a significant step up in power and complexity. Builders often employ cutting-edge technology, custom-made components, and advanced materials to create competitive robots in this class. Middleweights matches are characterized by high-speed collisions, intricate weapon systems, and strategic gameplay.
A very popular weightclass that competes at Robogames.
(Robogames is an annual event and competition for various combat robot weight classes, hosted in Northern California.)
For detailed combat rules, visit sparc.tools online.
Heavyweight (250lb)
250lb weight limit!
Commonly referred to as Heavies!
Heavyweights, with a weight limit of up to 250 pounds (113.4 kg), are the largest and most powerful combat robots. These machines feature imposing designs, heavy armor, and devastating weaponry, including giant spinning discs, hydraulic crushers, and powerful flippers. Heavyweight battles are intense, with robots capable of causing substantial damage and delivering thrilling performances, making them the main attraction in robot combat tournaments.
Heavies compete at BattleBots and Robogames – the most expensive, destructive, and advertised weight class.
BattleBots is a heavyweight combat robotics TV show televised on the Discovery channel!
Robogames is an annual event and competition for various combat robot weight classes, hosted in Northern California.
For detailed combat rules, visit sparc.tools online.
Uncommon Weightclasses
There are some weight classes that exist but have few to no competitions available anymore. (It’s wise to avoid building for these weight-classes as they basically no longer exist due to lack of competitions.)
75G (Fleaweight)
15lb (Dogeweight)
110 kg (International Heavyweight)
For detailed combat rules, visit sparc.tools online.
2. Learn the different robot types
Wedge
Wedge robots (push-bots) have no active weapon (meaning it has a passive (wedge)”weapon”) and instead they rely on strategic and aggressive driving to cause their opponent to damage themselves (by pushing and wedging them).
Horizontal Spinner
Robots with a horizontal (kinetic) spinner have an active weapon, a disc/bar/overhead spinner/or undercutter, that spins horizontally to cause damage to their opponent!
Vertical Spinner
Robots with a vertical (kinetic) spinner have an active weapon, a disc/drum/bar/or saw, that spins vertically to cause damage to their opponent!
Drum Spinner
A drum spinner is a cylindrical weapon that rotates horizontally. The outer surface of the drum is equipped with sharp teeth or cutting edges. Drum spinners are known for their compact design and ability to deliver concentrated, high-speed hits. They can cause significant damage to opponents’ armor and internal components due to their concentrated impact area.
Full Body Spinner
Full body spinner (FBS) (kinetic spinner) type robots are exactly as the name implies. A FBS features an active spinning weapon covering its entire body (like a shell). This body spinning weapon provides an all-around attack, making it effective from any angle, however challenging to build especially for beginners.
Lifter
Robots with a lifter have an “indirect kinetic controlled weapon.” Meaning, a powered mechanism that lifts the weapon (that is usually a platform or wedge) in order to lift and cause opponents to damage themselves!
Flipper
Robots with a flipper have an “indirect kinetic launcher weapon.” Meaning, a powered mechanism (platform or wedge) that flips the opponent over like a pancake! In order to flip over and cause the opponent to damage themselves!
Overhead Saw
Robots with an overhead saw (kinetic) spinner, have an active weapon. The saw is typically attached to an arm, thus keeping the spinner “overhead” of the robot. The arm goes up an down, with the spinner spinning on the end. The idea is that the arm will go down and hit the opponent with the saw to cause damage to the opponent!
Hammer
Robots with a (kinetic instant controlled-force) hammer weapon have an arm attached to the robot that goes up and down. This arm typically has a heavy weight, knob, or spike, attached to the end of the arm. The arm is used to impact and hammer the opponent to cause damage!
Crusher/Clamp
Robots with a (kinetic controlled-force pressure) crusher weapon utilize an opening and closing jaw mechanism to crush their opponents and cause damage! (Imagine a crocodile, it open and closes it’s jaws to crush it’s prey, same goes for this type of robot!)
3. Learn the parts of a robot
Drive Systems
Wheeled Drive
It’s a common, straightforward design using wheels for movement, offering speed and agility. The wheels are powered by motors, and the robot moves in the direction the wheels rotate. The wheels can be directly powered by motors attached to axles, or indirectly by using chains and sprockets or using gears.
Tread Drive
Less common design, features continuous tracks (treads) for movement (like a tank!). Treads provide stability and better traction, making them suitable for various terrains. Motors power the treads, enabling the robot to move smoothly and navigate challenging surfaces.
Shuffle Drive
Shuffling robots are less common due to complexity. Shuffler drive systems are powered by motors connected to discs. These discs create a sliding or shuffling motion, allowing the robot to move sideways or diagonally. This movement style allows the robot to change directions quickly and offers a low profile, making it harder for opponents to target specific parts. Shufflers use a sliding motion, providing agility and strategic maneuverability during battles.
Walker Drive
Walking robots are less common due to complexity. Walkers us legs for movement, resembling a walking motion. These robots move slowly but can exhibit stability and unique walking strategies in combat. They are distinct due to their legged design, providing an advantage in terms of balance and controlled movements.
Uncommon Drive Systems
Magnets: This system uses a wheeled drive and magnets to hover the robot slightly above the ground, allowing the wheels to have reduced friction to perform swift and smooth movements. This drive system offers exceptional speed and agility.
Omni-Directional Wheels: Omni-wheels or Mecanum wheels allow movement in any direction without changing the orientation of the robot. This drive system offers exceptional agility and maneuverability.
Pneumatic Systems: Some robots use pneumatic systems to power their movement. Pneumatic actuators can provide rapid and powerful movements, useful for flipping, lifting, or self-righting mechanisms.
Crawler Tracks: Unlike continuous treads, crawler tracks are made of individual links. This design provides stability and traction, making it easier for the robot to navigate challenging terrains or resist pushing from opponents.
The choice of drive system depends on the robot’s strategy, the arena conditions, and the rules of the event and weight-class. Builders often experiment with different combinations to find the most effective drive system for their specific robot design.
Batteries
LiPo Batteries
Lithium Polymer (LiPo): Lightweight, high energy density, popular in combat robotics.
These batteries come in various shapes and sizes!
*Lithium Polymer (LiPo) batteries are becoming the go-to battery option for most weight classes. These batteries provide the highest energy density of all battery types that are commercially available. The downside to LiPo batteries is that they deal with damage poorly. There have been several incidents where a LiPo battery taking damage has resulted in a spectacular fire. If you’re planning to use LiPo batteries be sure to consider how you’ll protect them from damage as a battery fire will likely ruin most of the parts near the battery. LiPo batteries also tend to swell under heavy loading, so using padded elements in your battery mounts can help minimize the risk of damage when this swelling occurs.*
*SPARC Component Selection Guidelines*
LiFe Batteries
*Lithium Ferrite (LiFe) batteries are another common battery type. This chemistry does not provide the
same energy density of LiPo batteries, however it is still a substantial improvement over NiMh, NiCad,
and SLA batteries. LiFe batteries are also less reactive to damage which means unlike LiPo batteries
there are no major events that restrict the use of LiFe batteries.*
*SPARC Component Selection Guidelines*
Uncommon Battery Types
*Sealed Lead Acid batteries are still seen in the heavier weight classes. These batteries are heavy, but
they’re generally quite stable and can handle putting out large amounts of current without issue. SLA
batteries are mostly worth consideration for robots weighing 60lbs or more.*
*SPARC Component Selection Guidelines*
*Nickel Metal Hydride and Nickel Cadmium batteries have fallen out of favor in recent years as LiPo and
LiFe batteries have become available. These chemistries were the go to option for years in the smaller
weight classes. You may be able to get these batteries for less cost than LiFe and LiPo packs, but the
price difference is shrinking quickly and the massive weight increase for the same power output makes
them a less than ideal option for a new bot.*
*SPARC Component Selection Guidelines*
Electronics
ESC’s
Speed Controllers (ESC):
Speed controllers regulate power flow from the battery to the motors. They control the robot’s movement by adjusting the motor’s speed and direction, allowing precise control over its actions in response to user commands.
Recievers
The transmitter sends signals to the receiver, which interprets these signals and instructs the ESC;s accordingly. This wireless communication allows operators to remotely control the robot’s movements and functions during battles.
Transmitters
Transmitters are held by the operator, and send signals to the recievers.
Uncommon Electronics
NOTE: Always check event rules and weight-class rules before deciding which electronics to use!
Microcontrollers (e.g., Arduino, Raspberry Pi):
Microcontrollers are small computer chips that act as the robot’s brain. They receive signals from the operator’s remote control and translate them into specific actions, such as moving the robot or activating its weapons. Programmed instructions on the microcontroller dictate the robot’s behavior.
Sensors: Robots may be equipped with sensors such as gyroscopes, accelerometers, proximity sensors, or infrared sensors. These sensors provide feedback to the microcontroller, enabling the robot to detect motion, measure orientation, or sense nearby objects.
Camera Systems: Some advanced robots use cameras and vision systems for visual feedback. These systems can aid in navigation, targeting opponents, or detecting specific objects or colors.
Wireless Communication Modules: Apart from radio control systems, robots might incorporate additional wireless modules for communication with other robots or external devices. This communication can be used for team coordination or remote monitoring.
Sound Modules: Sound components like speakers or buzzers can be used for audible alerts or communication during battles.
LEDs and Displays: Light-emitting diodes (LEDs) or displays are used for visual indicators, displaying robot status, or providing feedback to the audience.
Voltage Regulators: Voltage regulators ensure a stable supply of power to various electronic components, preventing damage from power fluctuations.
Relays and Switches: Relays and switches are used to control high-power devices or systems, such as pneumatic weapons or specialized mechanisms.
Data Logging Devices: Some robots include data logging devices to record performance metrics and analyze the robot’s behavior and effectiveness in battles.
The specific electronics used depend on the robot’s purpose, design, and the preferences of the builders, as well as event and weight-class rules. Builders often customize their robots with a combination of these electronic components to enhance their functionality and performance in combat
Framing & Body
Chasis
NOTE: Always check event rules and weight-class rules before deciding what kind of chasis to build!
The chassis of a combat robot refers to the lower framework that holds the wheels, motors, and drivetrain components. It plays a significant role in determining the robot’s shape, size, and overall stability. Chassis designs vary based on the type of drive system used (wheeled, tracked, or legged) and the specific requirements of the robot. For example, a robot with a low-profile chassis might be harder to flip over, while a robot with a wider chassis could offer better stability. Engineers often experiment with different chassis designs to find the optimal balance between maneuverability and defense.
Framing
NOTE: Always check event rules and weight-class rules before deciding what kind of frame to build!
The frame of a combat robot serves as the backbone, providing structural support to all other components. It is typically made from sturdy materials such as plastic, steel, aluminum, or titanium, chosen for their strength-to-weight ratio. The frame needs to be robust enough to endure high-impact collisions and shocks during battles. Engineers meticulously design frames, considering factors like weight distribution, balance, and overall rigidity. A well-designed frame ensures that the robot can withstand aggressive attacks without losing its structural integrity.
Armor
NOTE: Always check event rules and weight-class rules before deciding what kind of armor to use!
The armor of a combat robot acts as a shield, protecting vital internal components from damage. Robot builders carefully choose armor materials based on their weight allowance and the types of opponents they expect to face. Common armor materials include plastic, hardened steel, aluminum, and sometimes titanium for higher weight classes. Builders often strategically place the armor to cover essential parts like motors, batteries, and electronics, ensuring these components are well-protected during battles. Balancing the weight between armor and other components is a critical consideration, as excessive armor might compromise the robot’s speed and agility.
Robot builders face a constant challenge in selecting the right materials for framing and armor. Plastic offers cushioning and ablative armor qualities, it’s light and replaceable, but has limited durability. Steel offers exceptional strength but adds considerable weight, affecting speed and agility. Aluminum provides a good balance between strength and weight but may not be as durable as steel. Titanium, although expensive, is lightweight and exceptionally strong, making it a preferred choice for high-end robots aiming for both strength and speed. The choice of materials significantly influences the robot’s overall performance, making it a critical aspect of the design and construction process.
In summary, the framing and body of a combat robot are pivotal in ensuring the robot’s resilience and effectiveness in battle. Builders carefully consider the materials, design, and placement of these components to create a robot that can endure intense combat while delivering powerful and strategic attacks against opponents.
Ablative Armor
NOTE: Always check event rules and weight-class rules before deciding what kind of armor to use!
Ablative armor in combat robotics refers to a specific type of protective shielding designed to absorb damage and dissipate the impact energy during battles. Unlike traditional armor, which aims to withstand direct blows, ablative armor is intended to sacrifice itself in the face of powerful attacks, gradually wearing away to absorb the impact force. This type of armor is often made from materials like foam, rubber, or plastic that can absorb and disperse energy effectively. When the robot is struck, the ablative armor absorbs the energy, deforming or breaking in the process, but it prevents the damage from reaching crucial internal components. Ablative armor serves as a sacrificial layer, providing a temporary shield that minimizes damage to the robot’s essential systems. Robot builders strategically place ablative armor in vulnerable areas, ensuring that the primary structure and vital components remain protected for as long as possible during combat. This innovative approach to armor design allows robots to endure formidable attacks, enhancing their survivability and prolonging their effectiveness in battles.
4. Learn manufacturing basics
3d Printing
3D printing is a process of creating three-dimensional objects from a digital file. It works by adding material layer by layer, allowing the creation of complex shapes. Think of it like printing a document, but instead of ink on paper, 3D printers deposit material to build physical objects.
1. How 3D Printing Works:
3D printing begins with a digital 3D model created using computer-aided design (CAD) software. This digital file is sliced into thin horizontal layers using slicing software. The 3D printer then reads each slice and creates the object layer by layer.
2. Types of 3D Printing Technologies:
- Fused Deposition Modeling (FDM): FDM printers use a thermoplastic filament that is heated and extruded through a nozzle layer by layer.In combat robotics, the following printing techniques are considered highly unconventional and are rarely seen in practical applications. It’s important to note that approximately 99% of all printing for combat robotics is accomplished using Fused Deposition Modeling (FDM) technology. FDM printers are widely recognized for their versatility and accessibility, making them the preferred choice for hobbyists and professionals alike. These printers are not only popular in the realm of robot combat but are also commonly found in households, enabling enthusiasts to bring their creative ideas to life. While other printing methods do exist, they are far less common in the context of robot combat due to factors such as complexity, cost, and limited availability of suitable materials.
- Stereolithography (SLA): SLA printers use a liquid resin that is cured (hardened) by a laser, solidifying the resin layer by layer.
- Selective Laser Sintering (SLS): SLS printers use powdered materials (plastic, metal, ceramic) and a laser to sinter (fuse) the powder together layer by layer.
- Digital Light Processing (DLP): DLP printers use a digital light projector to flash a single image of each layer across the entire build area simultaneously, curing the resin in one go.
3. Materials Used:
3D printers can use a variety of materials, including plastics, metals, ceramics, and even biological materials. Common plastic filaments include PLA, ABS, PETG, Nylon, while metal 3D printing often uses materials like titanium, aluminum, or stainless steel.
4. Applications:
- Prototyping: 3D printing is widely used in product development for creating prototypes and iterative designs.
- Customization: It allows for the production of customized products tailored to individual needs, like personalized medical implants or custom-fit fashion items.
- Manufacturing: Some industries use 3D printing for small-scale manufacturing of specialized components and products.
- Education and Research: 3D printing is used in educational institutions and research labs for scientific experiments and educational purposes.
5. Advantages:
- Rapid Prototyping: Enables quick and cost-effective prototyping, reducing product development cycles.
- Complex Geometries: Allows for the creation of intricate and complex designs that are difficult or impossible to achieve with traditional manufacturing methods.
- Reduced Waste: 3D printing is an additive process, meaning it generates minimal waste compared to subtractive manufacturing methods.
6. Challenges:
- Limited Materials: While the range of printable materials is expanding, 3D printing still has limitations compared to traditional manufacturing methods.
- Surface Finish: Achieving a smooth surface finish can be challenging, particularly with certain printing technologies.
- Speed: 3D printing can be time-consuming, especially for large or complex objects.
For detailed combat rules, visit sparc.tools online.
CNC Machining
CNC (Computer Numerical Control) routing and machining are advanced manufacturing processes that utilize computer-controlled machines to produce precise and complex parts from various materials such as metal, plastic, wood, and composites.
CNC Routing:
1. Definition: CNC routing is a subtractive manufacturing process that uses a computer-controlled machine to cut and shape materials into customized designs.
2. Components:
- CNC Machine: The core of the process, which includes a router (cutting tool) and a control unit.
- Cutting Tools: Various types of bits and cutters are used for different materials and cutting requirements.
- Workpiece: The material (wood, plastic, etc.) being cut into the desired shape.
- Computer-Aided Design (CAD): Designs are created using specialized software to guide the CNC machine.
3. Process:
- Design Creation: A 2D or 3D design is created using CAD software.
- Conversion to CNC Code: The design is translated into CNC-compatible code (G-code) that guides the machine.
- Machine Setup: The workpiece is secured on the CNC machine bed, and the cutting tool is installed.
- Execution: The CNC machine follows the programmed instructions to cut the material into the desired shape.
4. Applications:
- Woodworking: Crafting furniture, cabinetry, and decorative items.
- Sign Making: Creating intricate signs and lettering.
- Prototyping: Developing product prototypes from various materials.
- Plastic Fabrication: Cutting plastic sheets for various applications.
CNC Machining:
1. Definition: CNC machining is a manufacturing process where computer-controlled machines remove material from a workpiece to create a desired shape.
2. Components:
- CNC Machine: Similar to CNC routers but with different cutting tools (end mills, drills, etc.) suitable for metals and harder materials.
- Cutting Tools: Tools are made of high-speed steel, carbide, or other specialized materials for metal cutting.
- Workpiece: Metals such as aluminum, steel, brass, and alloys are commonly machined.
- CAD/CAM Software: Computer-Aided Design and Computer-Aided Manufacturing software are used for design and toolpath generation.
3. Process:
- Design and CAD Modeling: Detailed 3D models are created using CAD software.
- CAM Programming: Toolpaths are generated, specifying the cutting routes and depths.
- Machine Setup: The workpiece is mounted on the CNC machine, and appropriate cutting tools are loaded.
- Machining: The CNC machine precisely removes material according to the programmed toolpaths to create the final part.
4. Applications:
- Aerospace: Manufacturing components for aircraft and spacecraft.
- Automotive: Producing engine parts, gears, and other vehicle components.
- Medical Devices: Crafting precision parts for medical equipment.
- Tool and Die Making: Creating molds, dies, and specialized tools.
Both CNC routing and machining offer high precision, repeatability, and the ability to create complex shapes, making them vital processes in modern manufacturing across various industries.
For detailed combat rules, visit sparc.tools online.
Laser/Plasma Cutting
Laser cutting uses a focused laser beam to precisely cut through materials like metal, plastic, or wood by melting, burning, or vaporizing the material along the cutting path.
Plasma cutting uses ionized gas (plasma) to cut through electrically conductive materials like metal. The plasma torch creates an electrically conductive channel of ionized gas, forming a completed circuit and melting the material in the process.
Laser Cutting:
Laser cutting is a technology that uses a laser to cut materials, and it is widely used in industrial manufacturing processes.
1. How it Works:
- Laser cutting works by directing the output of a high-powered laser through optics and focusing it onto a specific material.
- The laser beam melts, burns, or vaporizes the material, resulting in a high-quality finish.
- Computer Numerical Control (CNC) systems guide the laser head to cut intricate patterns and designs with high precision.
2. Suitable Materials:
- Laser cutting is suitable for a variety of materials, including metals (such as steel, aluminum, and brass), plastics, wood, fabric, and glass.
- Different types of lasers are used for cutting different materials. For example, CO2 lasers are suitable for organic materials, while fiber lasers are excellent for metals.
3. Precision and Accuracy:
- Laser cutting offers high precision and accuracy, allowing for intricate designs and tight tolerances.
- It is capable of producing complex shapes and small holes that might be challenging with other cutting methods.
4. Advantages:
- Minimal material wastage due to narrow kerf width (width of the cut).
- No physical contact with the material, reducing wear and tear on the equipment.
- Can be easily automated for mass production, enhancing efficiency.
Plasma Cutting:
Plasma cutting is a process that cuts through electrically conductive materials using an accelerated jet of hot plasma. Here are the basics of plasma cutting:
1. How it Works:
- Plasma cutting involves passing an electric arc through a gas (such as nitrogen, oxygen, argon, or air) to create plasma.
- The plasma torch focuses the plasma stream and forces it through the workpiece, melting away the material and creating a cut.
2. Suitable Materials:
- Plasma cutting is primarily used for cutting metals, especially steel, stainless steel, aluminum, and copper.
- It is often used in heavy industry applications, such as in shipyards and metal fabrication shops.
3. Precision and Thickness:
- Plasma cutting is suitable for cutting thick materials, typically in the range of 1mm to 80mm, depending on the power of the plasma cutter.
- While it offers good precision, the cut quality might not be as high as that achieved with laser cutting.
4. Advantages:
- Faster cutting speeds compared to some other methods, especially for thicker materials.
- Versatile and can cut through a wide range of metals.
- Can be used for both manual operations and CNC-controlled automated systems.
Both laser cutting and plasma cutting are valuable techniques in modern manufacturing, each with its own set of advantages and ideal use cases. The choice between them depends on factors such as material type, thickness, required precision, and production volume.
For detailed combat rules, visit sparc.tools online.
Waterjet Cutting
Waterjet cutting is a manufacturing process that utilizes a high-pressure stream of water, often mixed with abrasive particles, to cut a variety of materials.
1. How Waterjet Cutting Works:
Waterjet cutting uses a pump to pressurize water, forcing it through a small nozzle at incredibly high speeds. When abrasive particles (such as almandine garnet) are mixed with the water, it forms an abrasive waterjet, which can cut through hard materials like metal and stone.
2. Types of Waterjet Cutting:
There are two main types of waterjet cutting:
- Pure Waterjet Cutting: This method uses only high-pressure water and is suitable for cutting softer materials like rubber, foam, or paper.
- Abrasive Waterjet Cutting: Abrasive particles are added to the water to cut harder materials such as metal, ceramic, glass, and composite materials.
3. Advantages of Waterjet Cutting:
- Versatility: Waterjet cutting can cut through a wide range of materials, making it versatile for various industries.
- Precision: It offers high precision and can create intricate designs with minimal material wastage.
- No Heat-Affected Zone: Unlike some other cutting methods, waterjet cutting does not generate heat, preventing alterations in the material’s properties.
- Environmentally Friendly: It is an environmentally friendly process as it produces no hazardous waste and uses minimal amounts of water.
4. Applications:
Waterjet cutting is used in various industries, including aerospace, automotive, manufacturing, architecture, and art. It is ideal for cutting materials that may be sensitive to high temperatures.
5. Limitations:
- Material Thickness: Waterjet cutting may not be efficient for extremely thick materials.
- Speed: While precise, it might not be the fastest method for bulk production compared to some other cutting techniques.
- Operating Costs: Initial setup costs and abrasive material expenses can be relatively high.
6. Safety Measures:
- Protective Gear: Operators should wear appropriate protective gear, including gloves and eye protection, to prevent contact with the abrasive stream.
- Proper Ventilation: Adequate ventilation is necessary to disperse the abrasive dust generated during cutting.
7. Maintenance:
Regular maintenance of the waterjet machine, including checking the nozzle and abrasive supply, is crucial to ensure optimal performance and longevity of the equipment.
Waterjet cutting is a powerful and versatile manufacturing technique with numerous applications. Understanding its basics can help in making informed decisions about its use in various industries.
For detailed combat rules, visit sparc.tools online.
Hand Tools
Combat Robotics Starter Tools:
- Allen Wrenches (Hex Keys): Essential for tightening hexagonal socket screws during assembly, ensuring secure connections in the robot’s structure.
- Pliers (Robogrips): Versatile grip pliers for holding, bending, and twisting metal components, aiding in precise adjustments during construction.
- Snips: Handy for cutting wires, metal sheets, and plastics, allowing builders to customize and refine robot parts with accuracy.
- FDM Printer: Fused Deposition Modeling (FDM) printers are essential for creating custom components and prototypes. They allow enthusiasts to design and manufacture intricate parts at home.
- Soldering Iron: A soldering iron is crucial for connecting electrical components. It enables precise and secure connections, ensuring the robot’s electronic systems function properly.
- Wire Strippers: Wire strippers are used to remove the insulation from electrical wires, allowing for accurate connections and preventing short circuits.
- Drill and Bits: A small handheld drill and various drill bits are necessary for creating holes in the robot’s chassis and other components, facilitating secure attachments and modifications.
- Wrench and Screwdriver Set: A set of wrenches and screwdrivers in different sizes are vital for assembling and disassembling the robot. They are essential for tightening bolts and screws securely.
- Calipers: Calipers are precision measurement tools used to ensure accurate dimensions of components, helping in designing parts that fit together seamlessly.
- Safety Gear: Safety glasses, gloves, and other protective equipment are crucial for ensuring the builder’s safety during the construction process.
Manufacturing involves the process of converting raw materials, components, or parts into finished goods that meet a customer’s expectations or specifications. Hand tools are essential components of manufacturing processes and are used for various tasks such as cutting, shaping, joining, measuring, and assembling materials.
Cutting Tools:
- Shears: Electric or manual tools for precise straight-line cutting of various materials.
- Angle Grinder: Handheld tool for cutting, grinding, and polishing metal and other materials.
- Dremel Tool: High-speed rotary tool for detailed tasks like grinding, engraving, and carving.
- Bandsaw: Power tool with a toothed metal blade for cutting curves and straight lines in various materials.
- Hacksaw: Frame tool with a fine-toothed blade for cutting metal, plastic, and wood.
- Utility Knife: Versatile tool for cutting materials like paper, cardboard, and plastic.
- Snips: Designed for cutting sheet metal, available in different types.
- Files: Abrasive tools for shaping and smoothing metal, wood, and plastic surfaces.
- Wire Cutters: Used in electrical and electronic applications for cutting wires.
- Center Punch: Creates precise starting points for drilling, ensuring accurate hole placement in components.
- Heat Gun: Emits hot air for tasks like drying paint, shrinking heat shrink tubing, or softening adhesive.
- Deburring Tool: Removes sharp edges and burrs from metal, plastic, or other materials after machining.
- Tapping Tool: Creates internal threads in a hole for secure screw or bolt insertion.
Sanding and Finishing Tools:
- Belt Sander: Power tool with a sandpaper belt for rapid material removal and shaping large, flat surfaces.
- Disc Sander: Features a rotating abrasive disc for shaping curves and refining details in woodworking and metalworking projects.
- Orbital Sander: Handheld tool with a random orbital motion for smooth finishes on various materials, including wood, metal, and plastic.
Measuring and Marking Tools:
- Tape Measure: Flexible ruler for accurate measurements.
- Calipers: Precision tools for measuring distances between opposite sides of an object.
- Squares: Ensures right angles during assembly or marks right angles for cutting and shaping.
Assembly and Fastening Tools:
- Screwdrivers: For turning screws, available in various types and sizes.
- Wrenches: Tools for gripping and turning nuts, bolts, and fasteners, including adjustable, socket, and combination wrenches.
- Pliers: Gripping tools for holding, bending, and cutting materials, such as needle-nose, cutting, and locking pliers.
- Soldering Iron: Heats and melts solder, bonding surfaces together in soldering.
- Soldering Gun: Used for soldering electronic components.
- Allen Wrench (Hex Key): L-shaped tool for driving bolts and screws with hexagonal sockets.
- Crimping Tool: Joins metal pieces by deforming them to hold the other.
- Clamps: Hold workpieces together to prevent movement during operations like gluing or welding.
- Vise: Secures objects tightly for work to be performed on them.
- Scraper: Removes unwanted material from surfaces, such as paint or rust.
- Mallet: Soft-headed tool for minimizing damage during striking operations.
Machine Tools:
- Drill Press: Fixed machine for accurate and consistent drilling.
- Bench Grinder: Stationary tool with abrasive wheels for sharpening or shaping metal.
- Thread Die: Creates external threads on rods or pipes for plumbing and metalworking.
Specialized Tools:
- Countersink Bit: Drill bit for creating depressions to accommodate screw heads.
- Torque Wrench: Applies specific torque to fasteners, ensuring correct tightening.
- Welding Machine: Joins materials, usually metals, by melting workpieces and adding filler material.
Understanding how to select and use these tools is fundamental in manufacturing. Safety precautions and proper techniques are also essential to ensure efficient and accident-free operations. Always follow manufacturer guidelines and wear appropriate personal protective equipment when working with hand tools.
For detailed combat rules, visit sparc.tools online.
5. Learn commonly used materials
3d Printed Materials
PLA
PLA (Polylactic Acid):
Commonly used in robotics!
It comes in various colors and is environmentally friendly due to its biodegradability.
PLA is a biodegradable thermoplastic made from renewable resources like corn starch.
It’s easy to print with, requiring lower extruder temperatures and minimal warping.
PLA is suitable for a wide range of applications, including prototypes, toys, and decorative items.
PLA+
PLA+ (Polylactic Acid Plus):
Commonly used in robotics!
PLA+ is available in various colors and retains PLA’s eco-friendly nature as it is derived from renewable resources.
PLA+ is an enhanced version of PLA filament, designed to address some of PLA’s limitations.
It offers increased strength, toughness, and heat resistance compared to standard PLA.
PLA+ maintains the ease of printing associated with PLA while providing improved mechanical properties.
It’s suitable for applications where higher durability and impact resistance are required, such as functional prototypes and mechanical parts.
TPU
TPU (Thermoplastic Polyurethane):
Commonly used in robotics!
It is resistant to oils, greases, and solvents and maintains flexibility in low temperatures.
TPU is a flexible filament with rubber-like properties, offering high elasticity and abrasion resistance.
Nylon
Nylon:
Commonly used in robotics!
Applications include gears, bearings, and parts requiring high tensile strength.
Nylon filaments are known for their high strength, impact resistance, and flexibility.
They have excellent layer bonding and are resistant to wear, making them suitable for durable components.
Nylon absorbs moisture, affecting print quality, so it needs to be properly dried before printing.
ABS
ABS (Acrylonitrile Butadiene Styrene):
Less commonly used.
ABS requires a heated bed to prevent warping and emits fumes during printing, necessitating good ventilation.
ABS is a strong and durable thermoplastic known for its impact resistance and toughness.
It has a higher melting point than PLA, making it suitable for applications requiring heat resistance.
PETG
PETG (Polyethylene Terephthalate Glycol):
Less commonly used.
It combines the ease of printing with PLA and the durability of ABS.
PETG is a transparent and strong filament with excellent layer adhesion and impact resistance.
It has low warping and is resistant to moisture, chemicals, and UV light.
PETG is suitable for printing functional parts, mechanical components, and visual prototypes.
Onyx
Onyx:
Less commonly used.
Onyx can be 3D printed using Markforged 3D printers, which are specifically designed to handle this advanced composite material.
Onyx is a unique 3D printing material developed by Markforged, known for its exceptional strength and durability.
It is made from a combination of nylon and chopped carbon fiber, resulting in a material that is stronger and stiffer than most standard 3D printing filaments.
Onyx is reinforced with continuous carbon fibers, making it ideal for producing parts that require high strength-to-weight ratios.
It has a sleek black appearance due to the embedded carbon fibers and is commonly used for functional prototypes, tooling, fixtures, and end-use parts.
Metals
Aluminum
Properties: Aluminum is a lightweight metal with good strength and excellent thermal conductivity. It’s highly resistant to corrosion due to its natural oxide layer. Aluminum alloys are available in various grades, each offering unique properties like increased tensile strength or improved machinability.
Applications in Combat Robotics: Aluminum is prevalent in mid-weight and lightweight combat robots due to its lightweight nature and reasonable strength. It is often used in chassis construction and various structural components. While not as strong as titanium, aluminum’s affordability and ease of machining make it a popular choice for hobbyists and builders in lower weight-classes.
Titanium
Properties: Titanium is a lightweight, high-strength metal known for its exceptional corrosion resistance and impressive strength-to-weight ratio. It has a low density, making it one of the lightest structural metals available. Additionally, titanium alloys retain their strength even at elevated temperatures.
Applications in Combat Robotics: In combat robotics, of all weight-classes, titanium is prized for its excellent strength-to-weight ratio. It offers robust armor options while keeping the overall weight of the robot manageable. Titanium plates are often used as armor plating, protecting vital components from damage during battles. Its resistance to corrosion is also advantageous in harsh combat environments.
S7 Tool Steel
Properties: S7 tool steel is an air-hardening steel known for its exceptional impact resistance and toughness. It can withstand high shock loads without fracturing and retains its hardness even at elevated temperatures.
Applications in Combat Robotics: S7 tool steel is ideal for heavy-hitting weapons in combat robots. Its ability to absorb impact without breaking makes it a favored choice for hammer-like weapons, axe heads, and other striking mechanisms. Robots in heavyweight and super heavyweight classes often utilize S7 tool steel to create devastating and durable weapons.
AR 400 & AR 500
Properties: AR 400 and AR 500 are abrasion-resistant steel grades with high hardness and toughness. They are quenched and tempered to achieve their excellent mechanical properties, making them highly resistant to wear, impact, and abrasion.
Applications in Combat Robotics: AR 400 and AR 500 steel plates are extensively used as armor plating in combat robots across all weight classes. Their superior hardness and toughness make them effective in deflecting or absorbing blows from opponents’ weapons. These materials are crucial in enhancing the survivability of combat robots, providing a formidable defense against various attacks and ensuring the robot’s longevity in battles.
Differences:AR 400:
- Hardness: AR 400 steel has a nominal hardness of around 360-440 Brinell Hardness Number (BHN).
- Properties: AR 400 offers good abrasion resistance, making it suitable for applications where the material is subjected to wear, such as scraping or sliding against other surfaces.
- Applications in Combat Robotics: AR 400 is often used in situations where moderate to low impact is expected. It can be utilized for armor plating in combat robots, especially in weight classes where opponents may not exert extremely high-impact forces.
Hardness: AR 500 steel is significantly harder, typically ranging between 470-530 BHN.
Properties: AR 500 offers superior hardness and wear resistance compared to AR 400. It can withstand higher impacts and abrasion, making it highly effective against heavy blows and sharp-edged weapons.
Applications in Combat Robotics: AR 500 is the preferred choice for armor plating in combat robots, especially in heavyweight classes. Its higher hardness ensures better protection against powerful opponents, reducing the likelihood of penetration or significant damage.
Magnesium
Properties: Magnesium is a lightweight metal known for its low density, making it one of the lightest structural materials available. It offers an excellent strength-to-weight ratio and good thermal conductivity. However, it is highly reactive and can corrode easily in certain environments, so it requires special coatings or treatments for protection.
Applications in Combat Robotics: While magnesium has exceptional lightweight properties, it is less common in combat robotics due to its reactivity and flammability. The high risk of ignition and difficulty in extinguishing magnesium fires make it a less favorable choice for combat robot armor or structural components, especially in environments where sparks and extreme impacts are common. Builders often prioritize materials like titanium, aluminum, and various steel alloys for combat robot applications due to their better combination of strength, durability, and safety.
Plastics/
Composites
UHMW
UHMW (Ultra-High-Molecular-Weight Polyethylene):
Applications in Combat Robotics: UHMW is commonly used for armor components, especially in the form of thick plates. Its resistance to wear and impact makes it ideal for absorbing blows from opponents’ weapons and protecting vital robot parts.
Properties: UHMW is a high-density plastic known for its exceptional abrasion resistance, low coefficient of friction, and high impact strength. It is self-lubricating and highly resistant to chemicals.
HDPE
HDPE (High-Density Polyethylene):
Applications in Combat Robotics: HDPE is utilized in combat robots for various applications, including structural components, weapon systems, and armor plates. Its combination of durability and ease of fabrication makes it a popular choice in lower weight-classes.
Properties: HDPE is a versatile plastic with good impact resistance, chemical resistance, and low moisture absorption. It is lightweight, durable, and easily machinable.
Tegris
Properties: Tegris is a high-performance thermoplastic composite known for its impact resistance, strength, and lightweight nature. It offers excellent chemical resistance and durability.
Applications in Combat Robotics: Tegris is utilized in combat robot armor due to its high impact resistance. It is often chosen for its ability to absorb and disperse energy, providing effective protection against heavy blows from opponents.
Carbon Fiber
Properties: Carbon fiber reinforced plastics combine carbon fiber with a polymer matrix, creating a material with high strength, low weight, and excellent stiffness. Carbon fiber composites offer exceptional mechanical properties.
Applications in Combat Robotics: Carbon fiber composites are employed in combat robots for lightweight yet strong structural components, weapon systems, and armor panels. They provide high strength-to-weight ratio, making them ideal for enhancing the robot’s agility and protection without adding significant weight.
Lexan/Polycarbonate
Properties: Lexan is a brand name for polycarbonate, which is a transparent thermoplastic known for its high impact resistance, optical clarity, and excellent strength. Polycarbonate is lightweight and possesses good heat resistance.
Differences: “Lexan” is a trade name for polycarbonate, so there is no inherent difference between the two. They share the same properties and are used interchangeably in various applications.
Applications in Combat Robotics: Polycarbonate (Lexan) is often used as transparent armor panels in combat robots, allowing for visibility while providing protection. Its impact resistance and clarity make it suitable for applications where a clear view of the internal components or the arena is necessary.
Getting ready to build!
6. Read the Rules
The rules can vary from event to event, but it’s good to familiarize yourself with the overall most popular rules of the sport. Once you find your local competition, you should be able to find the ruleset they use.
SPARC Rules
SPARC Rules are by far the most commonly used rules in the sport.
You will see updates to the rules as posts, and can see the various rulesets on the top right hand side of the SPARC forum.
NHRL Rules
NHRL has it’s own ruleset, and they do not coincide with the rules used by other events.
You can view them here.
7. Find Competitions
RobotCombatEvents.com
RobotCombatEvents.com is the most popular event website,
BuildersDB.com
The Builders Database website was the original event sharing website, but has less events listed now. Still a good resource to check as some events are exclusively on there.
8. Give Yourself Time
Don’t put off building!
The biggest mistake I see new builders make is estimating how much time some of these tasks can take.
Get some drive practice in!
Don’t let the first time the robot is driving be in the arena!
9. Find Communities to gain more knowledge
Facebook Group Links
Depending on the weightclass, a lot of the most active groups for the sport are on Facebook.
Discord Group Links
Probably the easiest way to find information and get knowledge.
Helpful Tips!
- If you’re overwhelmed with the number of options of parts in Robot Combat, Find a kit you love. If you’re doing okay, read the Repeat Robotics Combat Handbook instead!
- Read the competition rules, it’s okay if you don’t understand them right away, we’re all here to help. The most important thing to start with is to be safe.
- Build your first robot, whether it be a kit or from scratch!
- Find a local competition (robotcombatevents.com & buildersdb.com)
- Register for event & read the Get ready for your first competition guide & Some helpful tips and tricks
- Show up & Compete!
- Learn what went wrong, and improve