Introduction: Wall-E Robot

Picture of Wall-E Robot

This is my Wall-E project that I am currently working on it is 150mm x 150mm x 160 high, it uses a pair of Mattracks for motive power and two robosapienV2 hip motors. It will be controlled by a BS2P40 stamp CPU and will have the following functions described below.

I build robots quite prolific but my let down is programing "hopeless but learning" I have a friend at who is programing it for me, From this I hope to learn how this program is put together and eventually program myself. We are in the progress of designing the H-bridge for the motors using the L298 chip, The head is finished apart from his adorable eyebrows which wire or Muscle flex and pan/tilt has been run.

The main reason for building this project was to see if I could use parts from my stock of components that I have lying around my basement and electronics room, The only thing so far that I have had to buy is the Mattracks , uOLED screen and L298 H-bridge ic. Which GWJax is sending me. I was inspired to build this project after seeing a Pixar demo video and thought WOW what a neat bot to build.

I have been in R/C scale and other unorthodox aircraft for over 30yrs and modeling is my passion, so this comes in handy when creating something like Wall-E. I hope you like how it is coming along. I would also like to add that GWJax has been an inspiration to me on the programming side.The main construction of Wall-E is 5mm lite ply, sides,front,back and top, with 2mm balsa cladding on the sides with some 1.5mm ply to form the raised panels. Rivets were made using PVA glue watered down 40% and applied to the required area's with a sharp pointed rod, One dip will give you 3 rivets. The arms were constructed out of 1.5mm ply and balsa, and uses 4 of my Technics air rams back to back, The fingers were modded Technics angle beams covered in 1mm ply for the sides and balsa top and bottom.

The base is constructed out of 5mm Acrylic sheet as this is good for boring holes to mount your fittings. the head H'mmm a real challenge here, I had to draw it out first to get the pear shaped eye right then work from there. The main eye tube was a pair of alloy pill containers which worked out to be the right size for the head. The Blue LEDs x 6, 3 in each eye are mounted on a 5mm acrylic disc and inserted in the tube about 2/3rds down, then another Acrylic disc in front with the ping sonar in each eye.The ping sonar is from TX and RX had to be removed from the board [tricky and an extension lead [screened] run from the board to the Tx and RX in each eye. I was not sure at the time if this would alter the characteristics of the range, but after testing this was unfounded.

The eyes light up at present using a circuit which has a CDS cell and when you switch the lights of the eyes come on, GWJax may code this to work also with some other functions on Wall-E.Wall-E was finished with off the shelf spraykote enamel cans, grey primer, followed by antirust primer, then layered with yellow, rivets applied, then sliver over the rivet area, followed by an airbrushed rust over the rivets. The whole body was then rubbed with scotchbrite pads until the rust and some silver was showing through, then airbrushed with a mix of satin varnish and grey primer to give Wall-E that weathered effect.The head was done in a similar way but with different colors. Phew, I think that's it guys. Check out my web site. Robotic Madness

1. Use my Mattracks as the main drive unit
2. Motor drive gear motors using H bridge controllers
3. Pan/tilt head using Parallax ultra sonic ping
4. 3 GP2D12 IR edge detectors or similar detectors
5. raise and lower the arms as a pair [up and down only]
6. raise and lower the front door
7. [Maybe not sure yet] raise and lower the head
8.Use Parallax ping in both eyes
9. airbrush Wall-E to look authentic as possible.
10. Fit a uOLED in the front panel
11. Use a Parallax emic text to speech chip for wall-e's voice
12. Fit Ultra bright blue LEDs in Wall-E's eyes
13. Make a pair of H bridges for the drive motors
14. solar cell to charge batteries
15. voice changer circuit for Emic text to speech
16. Speaker

Step 1: Gear Motors

Picture of Gear Motors

RobosapienV2 Hip motors with bevel hex gear.

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Hex shafts fitted to motor

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Motors fitted to Mattracks

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Motors fitted to acrylic base

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Alloy brackets fitted to acrylic base

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5mm lite ply base and sides

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Front and back ply added

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Extra side panels from 1.5mm ply, uOLED in front panel

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Solar led recharge panel right

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Front panels now in place

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Laminated side panels 1.5mm ply

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Technics LEGO rams for the arms, glued back to back

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1.5mm ply box to cover the rams

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Various layers to represent the metal panels

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Side panels now glued in place

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Arms in place

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Door and grippers now in place

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This is the eye section, four 1.5mm ply formers

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Two alloy pill containers and formers

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Ply formers glued in place on the alloy containers

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Formers now covered in balsa, and back sections added

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More balsa added to the rear

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Neck section made out of 1.5mm ply

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Internal formers to accommodate servos

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Ply box joined together and 1.5 mm balsa glued around the edges

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Balsa detail added to the neck

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Pan/tilt servos head and neck ready for assembly

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Neck added to the head via pan servo

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Tilt servo added at the base

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All parts ready to put together

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Main body primed ready for painting

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2nd stage of priming, rust brown

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Rivet detail is watered down PVA glue 40% and applied by a sharp nail

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Gripper detail, 3rd stage silver applied

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Silver applied over rivet detail

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A lot of detail is now coming together, 4th coat yellow applied and weathering starting to take place

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Rams at rear, and weathering taking place, using scotch brite pads.

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Arm detail now added, and front door, more weathering also done

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Wiring for the 6 LED blue lights in his eyes

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Internal discs for the eyes, these are inserted in the alloy tubes and house the LEDS, front rings are for the Ping sonar

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Wiring the LEDS

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Wiring loom and ping sonar now installed

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Weathered detail of Wall-E and ping sonar eyes

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Head/neck attached to body

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almost finished Wall-E

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Here's looking at you

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Wall-E's eyes lit up


NealKipper (author)2013-09-26

This is terrific! I love Wall-E!

makesomeso (author)2013-09-14

nice project. i love this robot. can wall e program with arduino??

sarathkumar (author)2012-08-11

How much money I make is a robot.
Think how the robot is capable of speaking skills
Please tell me sir
Teach me the way sir

Anthony312 (author)2008-07-10

what you could do is place some cameras in the eyes so u can see what wall-e sees.

4mem8 (author)Anthony3122008-07-10

Anthony312: i could have and that would have been cool, BUT, I decided to insert Ping ultra sonic sensors instead as I though collision avoidance would be better option. Thanks for you interest.

Anthony312 (author)4mem82008-07-15

ok i can understand that. But i saw these cool cameras that would fit in wall-e's eyes and still leave room for motors and wires and stuff. they're only 0.3 in. by 0.3 in. by 0.4 in. And when i watched some wall-e videos closely, i found out that the lense part of wall-e is hollow, which means it can be use for zoom and focus. this also helps when wall-e has to turn into a cube.

4mem8 (author)Anthony3122008-07-15

That would be cool also, but I had no room left after installing the Blue LEDs and ping sensors.

Anthony312 (author)4mem82008-07-15

oh...ok then. but im going to build my own wall-e robot, and im going to use cameras (and if there's room ill even do that LED and sensor thing like you did) and it will have one special feature that no other wall-e robot (that ive seen so far) has ... it can turn into a cube!

Anthony312 (author)Anthony3122008-07-15

though im working on how he would be able to compact trash (thats for later).

CapnTac (author)Anthony3122008-07-18

I hope you put up an instructable for it! Good luck making him roll up into a cube, that seems really hard. For the trash compacter thing, simply put metal squares on pistons inside of him, then when you put the trash inside of him, you could activate the pistons, and he would compact the garbage. Just a brainstorm.

4mem8 (author)CapnTac2008-07-18

CapnTac: It will be harder than he thinks, With all my electronics,motors,servos and batteries you could not fit a fly in there.

Anthony312 (author)4mem82008-07-21

I know exactly how hard this build is going to be. I am well aware of the space effiency of wall-e too. The reason you have no room is the size of your motors and servos and maybe even the electronics. They make smaller motors you know. and why do u need that huge gearbox attached to your motors when you can just connect the motor directly to the mattracks without the gears. and you can use a smaller recorder for wall-e's speach. When i examined wall-e the eyes only take about as much room as the bottom of the solar charge level screen up, and the tracks take as much room as the hollow trash compactor inside wall-e, which happens to start from the bottom of the solar charge level screen down. And his eyes are not as wide as the entire of wall-e itself, as a matter of fact it is 2 wall-e arm widths smaller. so as far as i can tell, wall-e turning in and out of a cube is plausable. There is even room for the solar pannels (they can replace the battery if you charge up long enough) and one or two small microchips fit (you can use 1 for speech and 1 for charge-up panal).

GWJax (author)Anthony3122008-08-19

WoW I just read all your comments, I am working side buy side with 4mem8 on this project as he has built him and I'm doing the programming for it. Just a little FYI for you, there is alot more to this than just adding a few micro chips. plus 4mem8 had used those gearbox motors for torque issues being that the Wall-E is not that light. Even if we use SMD's to make all our boards there still will not be enough room to box him up. CGA is a great thing to play with but in real life the physic just arn't there for that to happen. But I hope you do find a way to make it as I will be looking out for a wall-e that can move around it surondings and then box its self up. Good Luck Jax

4mem8 (author)GWJax2008-08-19

Anthony312. You have to realize one thing that is stated in the opening section on Wall-E, This robot has a criteria, And that is he had to be made with minimum bought parts, That is anything I could find around my basement, the only things I had to buy were the Mattracks, Lm 298 motor controller, some fast recovery diode's the rest I had around my workshop. Yes I could have bought SM boards and made it smaller, You cannot emit the gearbox's it would not work, You have to have torque to move this sucker. One of the reason's it won first place here and first place on Trossen robotics probably was due to the fact that it was basicaly home made and NOT from of the shelf parts. GWJax Thank you for chiming in here to explain to Anthony 312 the process of Wall-E.

GWJax (author)4mem82008-08-19

no problem 4mem8 I hope he does make one that will box up, I guess if you enlarge it enough you might beable to do this but the tracks must also reform them selfs. A very hard project even for the best. Jax

Anthony312 (author)GWJax2008-08-21

I know about the reforming tracks problem too. My prototype wall-e that I'm working on right now is too small to reform its tracks so they're going to be cubed in the way they are instead of changing its shape. on the larger wall-e I hope to make the tracks able to reform when going into cube form.

Luna! (author)Anthony3122012-02-22

jezzz christ... you remind me of my ex..

just congrat the man!!!!

Anthony312 (author)Luna!2012-02-22

I'm sorry. Congradulations on the Wall-E Robot!!!

GWJax (author)Anthony3122008-08-22

Anthony312 Keep us up to date with your progress, I know your protype will probly not have any electronics on it which is fine, But at least you can see that retraction of the tracks are needed and if you keep your wall-e light enough you may not need the gearbox motor, I would use a standard servo for the drive system in this case. Just remember to keep it as light as possable. When you get it right you'll have to enlarge the Wall-E 2 to 3 time the size of 4mem8's wall-e just to get everything inside. Good luck and I hope to see you get it done. Jax

Anthony312 (author)GWJax2008-08-23

My first wall-e (the prototype) will be made of cardboard. I chose cardboard because I have like 20 small cardboard boxes that are just the right size for wall-e. They are about the same size as the wall-e toys from Toys R Us, so they're perfect. for the motors that move wall-e I will use those small motors u find in hand-held fans or small toys and RC cars. I will use rubber bands for the tracks on the prototype wall-e and then get real tracks for the full-sized one. The head I will make out of two of the rectangle cameras I talked about earlier and two mini-motors (they are really small) for the lens to pop in and out. also I might put a motor on the hinge between his two eyes so he can do that up and down movements with his eyes like he does in the movie. On the larger version I will put a small laser pointer on his head because he has a laser in the movie (of coarse I wont use a REAL laser). I will use 4 rectangular orange LEDs and 1 regular LED for the solar charge-up panel. I will try and find a speaker for wall-e too (if I want to make wall-e talk or just so he looks authentic). I don't know what the red button on wall-e does in the movie so I will use that button as the on and off switch. I'll also use a mini-motor to open and close wall-e's front door. For the prototype wall-e I will use 8 small calculator solar panels (wow thats a waste of 8 calculators!) and for the bigger one ill try to find real solar panels. I'll also use mini-motors for the arm and neck movements too. The mini-motors will also be used to lift up wall-e and bring his tracks and arms in. I don't think ill make him compact trash on both wall-es. But there is an empty space in wall-e when he's not in cube form that you can put stuff in (just remember to take them out before making wall-e go into cube form!).

Anthony312 (author)GWJax2008-08-21

I've read your comments too, I know that your helping 4mem8 program his wall-e. anyway about the torque, I'm planing to make a much smaller wall-e than 4mem8 and thus am going to use a smaller motor and less power and torque, so a HUGE gearbox isn't neccesary. I'm planing on first making a small toy-sized prototype wall-e (to see if he can go into cube form, which I know he will), then later, if I have a lot more money and parts, will make a full-size wall-e (by full size I mean about the same size as 4mem8's wall-e). The prototype wall-e is the one I'm making plans on right now.

Anthony312 (author)CapnTac2008-07-21

But the Metal squares will crash into each other, and plus they will leave no room for the rods that will bring wall-e's tracks up when he has to turn into a cube. plus the metal squares wont leave room for the tracks themselves. Anyway it doesn't matter, i dont care about the trash compacter as much as i want wall-e to go into cube form. Thats what i want most.

4mem8 (author)Anthony3122008-07-21

Before I answer your question, How many robots have you built??

Anthony312 (author)4mem82008-07-24

I have never had the time or the money to completely finish a robot, but I have made many electrical circuits and contraptions with the parts I have laying around on my desk. I don't have enough money (or time) to buy all the parts I've needed to complete a robot, and I already have plans with what to do with the cluttered junk on my desk (I'm going to combine it all into one electrical contraption) so I'm out of parts basically. I also don't have the time to finish a robot because I'm very busy with school and homework and reading books and watching TV and playing on the computer (like I'm doing right now). So right now I'm just researching and making plans for all the robots I will be building in the future (which of coarse includes wall-e) and making sure they're all foolproof. I've lost count with all the plans for the robots I'm going to build. So I'm waiting until I have the time and the parts to finish a robot.

4mem8 (author)Anthony3122008-07-24

Great, pleased you are into robots, Take your time and do it right.

Anthony312 (author)4mem82008-07-26

Thanks. Now what were you going to say earlier?

4mem8 (author)Anthony3122008-07-26

Ok, What I am about to say is [ Please don't take this the wrong way ] When you have finished building a robot,[ A true robot ] from start to finish including programming you will see that it is NOT easy to do, Wall-E is a very complicated robot to build and to do what you are thinking of doing is pretty much on the top end scale to get working, I will not say impossible because there is no such thing as impossible, BUT what you are asking is getting pretty close and if you pull it off I for one will congratulate you Anthony312. Good luck and I look on with interest.

Anthony312 (author)4mem82008-07-27

I know how hard its going to be to build. But don't worry, i've got a whole lifetime to build it. It will be finished sooner or later...and thats a promise!

Anthony312 (author)Anthony3122008-07-27

But lets get back to what i was saying earlier. do u have anything to say about the comment i stated after yours to CapnTac (its the comment at the bottom of this conversation) and if you do, please reply on that one, this one is getting cramped.

SnuffyDaPenguin (author)4mem82009-06-24

Not sure if you're still working on this project, but I suggest mounting a camera just between and below his eyes, between the two sockets. Then he can have collision avoidance and could be followed/watched from a computer anywhere you wished.

dfelisilda (author)2011-10-27

love it <3....

jirus95 (author)2008-07-28

just saw it I loved it!!!

4mem8 (author)jirus952008-07-29

jirus95: many thanks for you comments.

ganeshsanjeewa (author)4mem82011-08-27

Nise work Dud!
Maxxa robot aha!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!1

Ltcheesecracker (author)4mem82008-08-01

u forgot the WALL-E logo on his chest!

4mem8 (author)Ltcheesecracker2008-08-01

Ltcheesecracker: Very good spotting on your part, Wall-E is not quite finished yet and this will be the last thing to go on when it is. Thanks.

General FOL (author)2011-02-04

Hi, how is this project going?

4mem8 (author)General FOL2011-03-23

hi General, has been slow as i was made redundent and was out of work for 12 months, this delayed progress money wise. but i still have it on my robotic shelf ready to start again , ty for asking :-)

bears0 (author)2009-10-06

cool put a vid on it

DivideByZero (author)2009-05-27

Great work :) I probably won't ever get to make one, but it'd be so cool to have a life size WALL-E.

DivideByZero (author)2009-05-27

DarthVader: That can be classed as spamming, I think.

And no, I don't normally do that, I just felt the situation was appropriate for it :P

Or should it be "DivideByZero: And no, I don't normally do that, I just felt the situation was appropriate for it :P" ??

rorpen (author)2009-03-23

Stop doing that!! Are you copying and pasting?

neardood (author)2009-02-08

looks awesome I cant wait to see it in action

mg0930mg (author)2009-02-01

Yeah he knows that, why are you saying that to all his comments. Just cause he puts the name first.

Anthony312 (author)2008-12-02

Hey 4mem8 remember me? (If you dont my comments are below)They made a wall-e toy that could transform into a cube. I guess they beat me to it.

4mem8 (author)Anthony3122008-12-02

Anthony312: Got a link to it??

Anthony312 (author)4mem82008-12-27

no I just saw a commercial on tv and a toy review on youtube. It's not that great anyway. its spring powered not motorized and the head, arms, and tracks are smaller than normal in proportion to the body. you just press a button and the head, arms, and tracks come out, then you just push them back in.

Plasmana (author)2008-12-07

Haha, my plasma speaker is behind you... :-)

About This Instructable




Bio: a busy busy man with his hobbies lol.
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