Submitted by Mobile Makerspace for the Instructables Sponsorship Program
Step 1: Edit in Sketchup
This will allow the Sugru to stay in place indefinitely although it really does not need much help. I got the idea from the Sugru robot arm called FixBot where the notches are on the finger.
Step 2: Print the Leg
Step 3: Sugru Time!
Take a small ball of Sugru and smush it into the bottom part of the leg wrapping it around and pushing it into the grooves that are cut out in the bottom. Do not worry about forming a proper looking foot unless you really want one but I don't think it will do you any favors. It may actually get in the way.
Form the foot so it is sticking down in the shape you want and flatten the bottom so it sits flat when the bot is standing in it's natural position. I rounded the edges a bit to allow it to roll a bit as it walks like a natural ball on a foot.
I had a lady send me a bunch of really cool stuff from ComposiMold. It's a product that you can use to cast parts that you have printed (or anything else) and make a bunch of copies then microwave it and use it again. This saves tons of filament if you are printing something that requires a bunch of the same parts. Be sure to freeze your printed part first before making the mold otherwise you will warp your parts as instructed in the directions and videos.
Repeat by making more copies of the foot using the 3D printer or the mold process and add the Sugru forming the foot.
Once you have completed the legs and with the Sugru cured, continue with the rest of the assembly.