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Step 3: Folding TJBot (Part 1)

Now that your laser cut is ready, it's time to assemble TJBot. Folding the chipboard requires patience and your full attention! :-)

Make sure you set aside enough time for folding TJBot and don't rush. It's easy to make a mistake by folding the chipboard in the wrong direction, and reversing the fold will cause the chipboard to break off. Don't panic if this happens, as you can use scotch tape to repair the damage.

Please note that when folding the chipboard, the following tricks are helpful.

  • Use the edge of a table or a metal ruler to give yourself leverage when folding the seams
  • Don't overfold – use the smallest amount of pressure needed to make the seams start moving, but stop just when they start to give. If you use too much pressure, you may tear the seam.
  • Plan your folds – as the saying goes, "measure twice, cut once", make sure you are folding in the right direction before you begin your fold.

The following videos show an overview of how to fold the chipboard and assemble TJBot.

Begin by laying the chipboard on a flat table.

The first step is to fold TJBot's jaw. The jaw piece is the large one with the four "Fold Down" tabs at the corners. Pop it loose from the larger piece of chipboard.

Fold down the corners that say "fold down".

Next, fold down the rectangular piece connected to the "Fold Down" tabs. This will make a square shape between the rectangular pieces and the "Fold Down" tabs.

Now, fold down the other two rectangular sides. Fold the inner seam first.

Then fold the outer seam over the "Fold Down" tabs and punch down the little tabs into the holes to finish the section.

Congratulations, you've assembled TJBot's jaw! Set it aside for now.

Next up are TJBot's legs. Pop the two legs loose from the chipboard. The legs have long rectangular pieces with "Fold Up" and "Fold Down" written on them.

The legs are the most delicate pieces in the set and require patience and focus. Begin by folding the piece that says "Fold Up" in the upward direction. Next, fold down the piece that says "Fold Down". We have found it to be easier to fold the "Fold Up" piece first and then fold the "Fold Down" piece.

Now, insert the legs into the jaw. The legs go into the L shaped holes in the jaw until the "Fold Up" piece hits the base.

Insert the legs from the top of the jaw downward. It may take some force to push the legs through the holes.

Next, remove the leg brace.

The brace sits in the two rectangular holes in the legs underneath the jaw. It keeps the legs straight.

Now, remove the feet and place them before you as shown below.

Fold the side flaps downward (in the direction of the table), very weakly. The feet will form a triangle shape that attaches to the legs, so over folding may cause them to break.

Insert the feet into the notches in the leg as shown below.

Congratulations, you can now make TJBot stand on his own! You are now halfway through with the folding. :-)

<p>Would you please provide a few suggested online laser cutting services? After 30 minutes with google, I've yet to find one that is an obvious candidate for this particular job. Thanks.</p>
<p>Hi </p><p>Ponoko is an online laser cutting service where you could make this. I've formatted the files so you can easily make them. You'll see them here - <a href="http://www.ponoko.com/design-your-own/products/tjbot-lasercut-lines-v2-ponoko-p3-size-13901" rel="nofollow">http://www.ponoko.com/design-your-own/products/tjb...</a></p><p>*I work at Ponoko. Seen a couple of people trying to make these designs and having trouble as designs are not formatted for our software. I wanted to give specific Ponoko ready files to make it easier for people to make these parts if they don't have access to a laser of their own.</p>
<br>For the laser cut, we recommend using chipboard with dimensions 18&quot; x 18&quot; x .080&quot; (457mm x 457mm x 2mm). Corrugated cardboard is not a desired material for TJBot.<br>
<p>Where do you source the chipboard from? </p><p>Would 0.05&quot; chipboard work?</p><p>We'll look at adding it to our materials catalog so that people can order this more easily.</p>
<p>the correct cardboard can be purchased through www.texlaser.com</p>
<p>Please send us an email at tjbot@us.ibm.com to follow up.</p>
<p>Here's a link to the official laser cutters of TJBot. www.texlaser.com</p>
Used Ponoko, added glasses with tape on the inside to cover the camera when not in use. (Just in case the NSA wants to creep lol) A few components kept slipping out of place (like the feet), so I used just a tiny bit of glue. Everything else went perfectly. Yay!
<p>Lovely! It looks like you made this with cardboard instead of chipboard. We found the cardboard can be a little flimsy. How is yours holding up? Love the glasses! :-) </p>
Thanks! When it came from the cutter, it was thinner cardboard than I had intended, so I was worried, but it's great! it has a nice stable feel and I've been handling it a lot (taking pics and such) without any issues. I can't find a place that would cut the chipboard but if I make another, I would like to go that route to compare. Also, I think I'm going to plastidip this little guy and experiment with that.
<p>Many online laser cutting services require different colored lines for cutting versus engraving. How can the existing files easily be converted so that the cutting lines are blue and engraving lines are red. As we don't have the vector files it doesn't seem easy to do unless you redraw the image.</p>
<p>Hi do you mean solid vs. broken lines? All of the lines are supposed to be cut, no etching needed. Also, we have an EPS file in the download package that is a vector file that you can edit for each different need. You may download the vector file at <a href="https://ibmtjbot.github.io/images/TJBotLasercutLines.zip">Laser cut TJBot</a></p><p>Let me know if this doesn't help.</p>
<p>Are there any friends in Taipei knowing the 3D or Laser company can help on cutting service? </p>
<p>Where do buy material of TJBot?</p>
We have provided a list of electronics for each recipe with a purchase link on Amazon. Feel free to shop around. <br><br>For example https://www.instructables.com/id/Use-Your-Voice-to-Control-a-Light-With-Watson/ needs<br>* Raspberry Pi 3<br>* USB microphone <br>* NeoPixel RGB LED <br>* Female/female jumper wires <br>* IBM TJBot: You can 3D print or laser cut the robot<br>
<p>Awesome process piecing each part of the lasercut TJBot together!</p>

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Bio: I'm an open source project designed to help you access Watson Services in a fun way. You can laser cut or 3D print me ... More »
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