Eduardo Labastida Arce

A01700681 IMT

Case of study

1. Toe support

For the toe support we need a resin that is flexible. This is because if the toe
passed on an irregular path it will not break. The polyester resin is the best
option as it not as rigid as the epoxy. This thermoset resin. Its properties are:
• Corrosion resistance.
• Water resistance.
• Can withstand temperatures up to 80° C.
• Good for compression applications.

The reinforcement that will be used will be carbon fiber. This is because it can
withstand tensile loads. Also, because it is more flexible than other fibers after
they have been cured with the resin.

The polyester resin can be found in cans of 1 kg, 5 kg or up to 20 kg. However,

some cans of resin can be bigger. In the case of the carbon fiber a roll of 50
meters can be purchased.

The support must be hard, but flexible as it can be blend when the robot is
walking. That’s why a four layer can be possible, and it is hard enough to
withstand the loads as it is all distributed. In the case, of standing in one toe,
the support must be flexible enough to hold the shape. Also, this will make
the support light. The lamination plan will be the next one:

• First plane 45° angle.

• Second plane -45° angle.
• Third plane 0° angle.
• Fourth pane 90° angle.

The lamination is selected like that so it can withstand the load from any
direction, and it won’t break. Also, it will blend easily without having the risk
of breaking.

For joining the toe support to the leg, a Urethane adhesive can be used [1].
This product can bond composites and metals, in the case the leg has a metal
structure it will fit perfectly.
2. Toe

Also, for the toe, the polyester resin is going to be used. As all the weight of
the robot will be pointed to that direction it is important to resist and protect
the toe. Another reason for using it is because the shoes use polyester, so it
resists compression loads. Its properties are:
• Corrosion resistance.
• Water resistance.
• Can withstand temperatures up to 80° C.
• Good for compression applications.

For the reinforcement glass fiber can be used. It is not as flexible as the
carbon fiber, but it is good for compression applications, until 1080 MPa. Also,
it can be more elongated than the carbon fiber. With this reinforcement, the
toe will be able to resist the whole weight.

The polyester resin can be found in cans of 1 kg, 5 kg or up to 20 kg. However,

some cans of resin can be bigger. In the case of the carbon fiber a roll of 50
meters can be purchased. For the glass fiber it can be found in mats or more
complex fabrics. They have sizes from 3 x 1 m or 1.25 x 1.25 m.

In this case, the lamination plan will not be needed as the fabric will be mixed
until it takes the shape of the mold. A thickness of two or three inches it is
needed as the toe will be supporting the whole weight of the robot.

For joining the toe with the support an adhesive is the better solution as the
support has a composite material on its surface. An epoxy adhesive can be
used. The condition of this adhesive needs is that it needs to support high
impact strength. In this case, the brand Scotch-Weld offers excellent
properties.

3. Engine/ systems housing

For the engine cover the resin to use is the polyimide because of its properties.
This is a thermoset resin. The resin has a higher mechanical and temperature
resistance. Also, the reinforcement will be of aramid as it can withstand high
temperatures (melting point of 500° C approximated). So, the cover will be
good for resisting the high temperature of the motor (can be up to 300° C).
Some properties of the resin are:
• Good mechanical properties and retention at high temperatures.
• Good compression with graphite fiber reinforcement.
 • Inherently flame resistant.
• Unaffected by most solvents and oils.
• Can withstand until 260° C.
The fabric of aramid can be purchase as a roll and can be found as Twaron
Fabrics by the company TEIJIN. The fabric is plain and unidirectional (in for
this supplier). For the polyimide, it can be easy to find it as powder. This will
help to use the quantity needed, but no excess (to avoid waste).
In the case of the plane, we need that the cover is hard. If any movement
moves the motor, the cover can resist the impact. Another reason to choose
aramid (like Kevlar). This lamination plane it is planned to resist all the tensile
loads. That’s why the plane organization will consist in six layers.
• First plane 0° angle.
• Second plane 45° angle.
• Third plane -45° angle.
• Fourth plane 90° angle.
• Fifth plane 180° angle.
• Six plane 0° angle.

For joining the cover with the rest of the body and cabin (if it is needed), and
epoxy adhesive is the better solution. This material is like the one that can be
used with the toe and its support. The difference between these two comes
from the fact that it is has an excellent environmental resistance, excellent
fatigue performance and high impact strength (of supporting the cover while
the motor is working).

4. Pilot cabin

For the cabin the material intended is the Poly methyl methacrylate, known
as Plexiglas (commercial name) or acrylic, is a transparent thermoplastic
resin. This material has been used for the airplane windows since 1933. A
reinforcement will not be needed as the Plexiglas can be molded in the shape,
we want it. Also, because of its properties:
• Can be shaped easily.
• Lighter than glass and with a density of 1190 kg/m3. A little heavier
than water.
• Can pass 93% of light.
• Does not produce any toxic smoke.
• Can be repaired easily.
• Hard as aluminum.
• Thermal and acoustic non-conductor.
• High resistance to impact, from ten to twenty times than glass.
 • High resistance to environment and ultraviolet rays. It takes a long time
to age.

The Plexiglas can be purchased in sheets of different sizes. Depending on

the distributor the sizes can be bigger than the one found in small stores.

A lamination plane it is not needed as the material can be molded and

because of the properties mentioned above.

For joining the cabin to the rest of the body it is better to use bolts. Doing this
will let the material fix into the robot structure. With this we get sure that the
cabin will not move, and it can be replaced more easily. If it is needed to have
the cabin sealed plan acrylic adhesive can be use between the surface of the
structure and the Plexiglas.

5. Arm

In the case of the hand, as it needs to be resistant to any material when it is

interacting with the exterior, I will use as matrix the VICTRX PEEK, which is
a thermoplastic resin known as Polyether ether ketone. This material has the
next properties:
• High temperature performance.
• Excellent chemical resistance.
• Excellent heat distortion properties.
• Excellent resistance to thermal ageing.
• Low coefficient of friction.
• Lighter, but strong as metal.
For the reinforcement for the arm, carbon fiber is the best option to use. This
have to do with all the load the arm will be experienced, which are more likely
to be tensile. As it is known, the carbon fiber with resin has a much more
resistance to the loads that are going to be applied on it. Also, because of the
resin’s properties it will withstand all the environment. The carbon fiber will be
of an 8HS, so it will be more resistant.
For the resin, it is found in pellets, so boxes of the material can be
purchased. Each box has 25 kg. With this technique, the pellets can be used
whenever they are needed. For the carbon fiber, a roll can be purchased by
meter. So, 50 meters can be useful.
In the case of the arm, the structure must be hard. So, for the lamination plane
six fabrics are going to be used.
• First plane 0° angle.
• Second plane 45° angle.
 • Third plane -45° angle.
• Fourth plane 90° angle.
• Fifth plane 180° angle.
• Six plane 0° angle.
With this organization the arm will withstand any load, no matter in which
direction is it. Also, with the resin, the piece will be resistant to the
environment. With this, a double weight of its own is hope, to withstand it
without any problem. The lamination plane intends to resist all the forces
For joining the arm, the same epoxy adhesive use for the cabin is suitable
also in this situation. So, the Epoxy Adhesive DP420NS will be used.
6. Hand

In the case of the hand, as it needs to be resistant to any material when it is

interacting with the exterior, I will use as matrix the VICTRX PEEK, which is
a thermoplastic resin known as Polyether ether ketone. This material has the
next properties:
• High temperature performance.
• Excellent chemical resistance.
• Excellent heat distortion properties.
• Excellent resistance to thermal ageing.
• Low coefficient of friction.
• Lighter, but strong as metal.
These properties will ensure that the hand can withstand all the things it
touches. In this case, the hand has an inner structure, so the resin can
only be added without any problem. However, aramid can be used as
reinforcement for the fingers and the palm. This is because it can be elastic,
can withstand high tension loads and it is hard to break.
The fabric of aramid can be purchase as a roll and can be found as Twaron
Fabrics by the company TEIJIN. The fabric is plain and unidirectional (in for
this supplier). In the case of the resin, it is found in pellets, so boxes of the
material can be purchased. Each box has 25 kg. With this technique, the
pellets can be used whenever they are needed.
As the hand needs to be flexible enough for not to break, one or two laminas
can be used. If that is the case, the two laminas will be place like this:
• First lamina with a 45° angle.
• Second lamina with a -45° angle.
 This plan organization will help to withstand all the tensile loads. Now with the
resin cured, it will become a hard material that can withstand the materials
or loads.
By last, for joining the hand with the arm that may have in the end a metal
structure the same adhesive or urethane can be used. As it was mentioned in
the support toe, this adhesive will give us the characteristic of bonding the
metal with composite or composite-composite

References
[1] 3M. (2016). Need and Adhesive to Bond Composites?. Available in:
https://multimedia.3m.com/mws/media/1282948O/3m-scotch-weld-composite-urethane-
adhesive-selector-tool.pdf
[2] 3M. (2016). Need and Adhesive to Bond Composites?. Available in:
https://multimedia.3m.com/mws/media/1282948O/3m-scotch-weld-composite-urethane-
adhesive-selector-tool.pdf
Amazon-Victrex. (2016 May 21). Victrx Peek 450G Natural (Poly Ether Ether Ketone) resin.
Available in: https://www.amazon.com/VICTREX-Natural-Ether-Ketone-
resin/dp/B01FZXLKKU
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Wikipedia. (2018 August 10). Thermoset polymer matrix. Available in:
https://en.wikipedia.org/wiki/Thermoset_polymer_matrix#Bis-maleimides_(BMI)
Wikipedia. (2019 March 25). Polyester Resin. Available in:
https://en.wikipedia.org/wiki/Polyester_resin