Introduction: Robot Cloning by DIY 3d Printers!

About: Mike's Bio: He is a computer programmer by day and an amateur roboticist by night. Mike and his humanoid robot Boomer have competed in the last six Robogames and have won multiple bronze, silver and gold metal…

The DARwIn-OP is a open hardware and software project which greatly aided me in doing this project.

        DARwIn-OP is an acronym for (Dynamic Anthropomorphic Robot with Intelligence - Open Platform) or DARwIn for short. The DARwIn-OP was developed by the RoMeLa research lab at Virginia Tech in collaboration with University of Pennsylvania, Purdue University and ROBOTIS. ROBOTIS is a world leading South Korean robotics’ company. Their Dynamixel servos are the leading robotic servos in the world and the key to why the DARwIn-OP is so ground breaking. The lead designer of the DARwIn-OP project has Dr. Dennis Hong of Virginia Tech’s RoMeLa and ROBOTIS. The robot is a state of the art research and development humanoid robot. The DARwIn-OP weighs in at about 2.9 kilograms and a height of 45.5 cm.

The idea behind this project is to find new and cheaper ways to create and build robots. As 3d printing becomes cheaper and easier to use more and more people will have access to this way of manufacturing. I hope that this instrucable will  open up more peoples eyes as to the power of this new personal fabrication method.

Below is a link to my Make magazine article on how I made the clone.

Step 1: Why I Wanted to Own a DARwIn-OP!

I thought it would be a good idea to show a production version of the DARwIn-OP in action to show the reason why I wanted this cool robot.

This is video of the DARwIn-OP in its natural environment Robocup soccer.

Step 2: Download CAD File

First step was to download all of the 3d CAD files.

Link to file location.

Other download information links

Step 3: Create .STL Files for All of the Parts.

I used Autodesk Inventor to create my .STL files, you can use your favorite 3d design software.

If you need a cheaper way try AutoDesk 123D Beta if you can still download it.

Here is a link to my Thingiverse project page for my DARwIn-OP clone where I have upload all of the .STL files for the robot.

Step 4: Print Out All Parts on a 3d Printer.

I used the UP! Plus 3d printer to print out almost all of the robot, again you can use a 3d printer that you own or have access to. This took me almost two months to get all of the parts printed out correctly. 

UP! Plus 3d printer.

The Afinia H-Series: 3D Printer is the exact same printer.

Step 5: Buy the Electronics for the Robot.

Link to website.

The easiest part of this project.

Step 6: Buy Your Servos for the Robot.

Yes the MX-28T servos are expensive but they are state of the art robotic servos. The servos of your robot are alwas the key as to how well your robot will preform.

Link to where to buy them.

Step 7: Buy Fastners for the Robot.

It may not seem like it but this was one of the hardest parts of this projected. I was aided by the detail list in the assembly manual. After a lot of phone calls and e-mails and internet research I found McMaster-Carr in Chicago was the best place to order fasteners from.

Step 8: Assembly Robot

The DARwIn-OP has three very detail manuals that you can download. They are an Assembly, Wiring and Fabrication manuals. 

Step 9: Download Software to Robot and Laptop

The control software is open source and works on windows and Linux.

DARwIn-OP support website.

Step 10: Turning on Robot for the First Time

This is always a very scary moment when doing this for the first time.

Step 11: Test the Robot

This is also a terrifying moment but it can also bring great joy!

Step 12: Redesign Parts That Break

This brings out the great advantage of personal fabrication. The ability to make part after part until you get it right or iteration.

Step 13: Print Out New and Improved Parts

How cool is it to have a 3d printer of your own!

Step 14: Reassembly Robot With the New Parts.

I like building robots so I enjoy this part!

Step 15: Retest Robot With New Parts.

This can be boring but it has to be done.

Step 16: Loop

Do While ( robot Fails )

     CALL step 12,
     CALL step 13,
     CALL step 14,
     CALL step 15,

Step 17: Robot Is Working!

If you are like me, you will we always be going back to step 14 because of new ideas or ways to make your robot better.

Total cost for my project was 6000 USD if you don't include the 3d printers that I used. A lot of money yes but if you buy a factory made DARwIn-OP from Robotis the cost is 12,000.00 USD. So I saved about 50% of the cost of the robot by building it myself.

If you are interested in following future upgrades and mods to this robot you can check out my blog.

Video of the robot walking:

Step 18: Future Upgrade Possibilities.

Modifying the covers of the DARwIn can lead to some interesting modification ideas. 

Simplest would be changing there color to hardest which would be modifying their design.

A great example is changing the color of the covers to mimic the Ironman power suit.

Jet-pack and weapons for the power suit may take some more time and research.

The images where created in AutoDesk Inventor by my friend Yoshihiro Shibata.

UP! Contest

Participated in the
UP! Contest