Step 1: Design
I found this design of the finger on the net which allows a single servo to provide full motion of curl of a human finger.The design works best when Aluminium is used for the cut outs of the fingers, but as I had perspex available I went with the weaker option which resulted in brittle fingers.
All the fingers are the same design but a variation of measurements, except for the thumb. they can be found below:
The designs below are the ones I sent through to a laser cutter here in Johannesburg for about R350 for all cuts and material.
they required the files to be sent in 2d DXF format, so if you alter the design in sketchup, make sure you export it in the correct format.
The rest of the cut outs are made up of wrist and palm sections.
index finger, middle finger, ring finger is roughly the same size.
pinky is slightly smaller than other fingers.
Thumb has different dimentions