Introduction

Designing a Robot Chassis is a critical step in robotics projects. The chassis provides the structural framework to mount and protect the robot’s components. Specialized software makes it easier to design custom robot chassis to fit your exact specifications and requirements.

In this comprehensive guide, we’ll cover everything you need to know about robot chassis design software. We’ll discuss the key features to look for, compare some of the top software options available, and walk through the typical workflow of designing a chassis using CAD software. By the end, you’ll have a solid understanding of how to leverage software to create an optimal chassis for your robot.

What is a Robot Chassis?

A robot chassis is the base frame and structure of a robot that provides mounting points and protection for the robot’s internal components, such as the motors, batteries, electronics, and sensors. The chassis is the robot’s “skeleton” upon which everything else is built.

Some of the key functions and characteristics of a well-designed robot chassis include:

• Provides a strong, rigid structure
• Allows precise mounting of motors, wheels, and other components
• Protects internal parts from damage
• Enables desired mobility (wheeled, tracked, legged, etc.)
• Constructed from suitable materials (metal, plastic, etc.)
• Considers weight, strength, and cost constraints

Chassis can be constructed from scratch or built from off-the-shelf kits and parts. Either way, using CAD software to model and design the chassis digitally before building it physically is highly recommended.

Benefits of Using Software to Design Robot Chassis

While it’s possible to design a basic robot chassis without any specialized software, using CAD (computer-aided design) tools provides many advantages:

1. Quickly iterate and refine designs
2. Create accurate 3D models to visualize the chassis
3. Easily add, modify, and rearrange components
4. Optimize weight, strength, and other properties
5. Catch design errors before building anything physically
6. Generate 2D drawings and blueprints
7. Directly interface with CAM and rapid prototyping machines

Choosing Robot Chassis Design Software

Many different CAD software packages can be used to design robot chassis, each with its own strengths, weaknesses, and target uses. When evaluating chassis design software, consider these key factors:

3D Modeling Capabilities

At its core, robot chassis design software must provide robust 3D modeling tools to create digital representations of the chassis structure and components. Look for software that includes:

• Solid modeling and surface modeling tools
• Parametric modeling capabilities
• Assembly modeling tools to combine parts
• Mechanical component libraries (screws, bearings, etc.)

Ease of Use and Learning Curve

Some CAD software is geared towards experienced engineers, while other tools cater to hobbyists, students, and less technical users. Consider how much time you’re willing to invest in learning the software and look for options that match your needs and skills.

Some CAD software offers more intuitive, user-friendly interfaces for easier adoption, while others provide advanced capabilities and customization for power users.

Compatibility and Interoperability

Consider how well the CAD software integrates with your existing tools and workflow. Some factors to look at include:

• Support for standard file formats (STEP, IGES, STL, etc.)
• Direct CAM integration for machining parts
• Plugins and add-ons for electronics design, simulation, etc.
• Ability to import/export designs from other software

Collaboration Features

If you’re working with a team, look for CAD software with built-in collaboration features that make it easy to share designs, track changes and revisions, and work together on the same model.

Cloud-based CAD tools are gaining popularity since they make real-time collaboration much easier compared to traditional desktop-installed software. However, cloud-based software usually requires a subscription rather than a one-time license.

Cost and Licensing

CAD software ranges from free and open-source to premium professional-grade packages costing thousands of dollars. Consider your budget constraints and licensing requirements.

For individuals and small teams, a low-cost or free package is usually sufficient. Larger organizations may need premium software with enterprise licensing and support.

Some popular entry-level options include Autodesk Fusion 360, FreeCAD, and SketchUp. Solidworks, Autodesk Inventor, and Siemens NX are popular premium packages geared toward professional engineers.

Typical Workflow for Designing a Robot Chassis

While the specific steps and software used can vary, designing a robot chassis generally follows this typical workflow:

1. Define Requirements and Constraints

Start by clearly defining the functional requirements and design constraints for the robot chassis:

• Size and weight
• Desired mobility and locomotion
• Power source and battery size
• Required sensors and electronics
• Environmental factors (terrain, temperature, humidity, etc.)
• Budget and materials

2. Conceptual Design and Sketching

With the requirements in hand, sketch out some rough conceptual designs for the chassis. Use pencil and paper or basic 2D drawing software to quickly generate and compare different ideas.

Don’t get too detailed at this stage – the goal is to explore different design directions before committing to a specific approach.

3. Create 3D Chassis Model

Using your CAD software of choice, create a 3D model of the chassis:

1. Create individual 3D parts (wheels, frame pieces, mounts, etc.)
2. Assemble the parts to create the complete chassis model
3. Add mechanical hardware and standard components
4. Assign materials to parts

Make sure to continually validate the 3D model against your design requirements. Use the CAD software’s analysis tools to check weight, clearances, interferences, and other key properties.

4. Integrate Electrical Components

Once you have a basic 3D chassis model, begin adding and integrating electrical components and subsystems:

• Motors and gearboxes
• Batteries and power management
• Microcontrollers and PCBs
• Sensors (encoders, gyros, Distance Sensors, cameras, etc.)

The chassis must provide suitable mounting points and access for each electrical component. Iterate on the design as needed to accommodate everything.

5. Detailed Design and Performance Analysis

With the basic chassis structure and electrical components modeled, move into detailed design and analysis:

• Add material properties and perform stress/strain simulations
• Optimize chassis topology to reduce weight
• Generate 2D drawings and blueprints
• Create exploded view drawings and assembly instructions
• Double-check all dimensions, tolerances, and fits

Use the CAD software’s built-in tools and add-ons to analyze and refine the detailed chassis design.

6. Prototyping and Physical Testing

Generate the necessary 2D drawings and 3D models to fabricate a physical prototype of the chassis. This may involve:

• 3D printing
• CNC Machining
• Laser cutting
• Assembling off-the-shelf components

Assemble the chassis prototype and perform physical testing to validate the design. Evaluate the chassis’ structural integrity, component fit, and overall performance.

Iterate on the CAD model and generate new prototypes as needed until the chassis meets all requirements and passes testing.

7. Final Design and Documentation

With a validated chassis design, create the final 3D model, 2D drawings, and documentation:

• Assembly drawings and bills of materials
• Manufacturing specifications
• User manuals and maintenance instructions

The final CAD files serve as the “master” reference for the chassis design. Make sure to properly organize and store these files for future use.

Comparing Top Robot Chassis Design Software

Now that we’ve covered the key considerations and typical workflow for chassis design, let’s take a closer look at some of the top CAD software options and compare their features:

Autodesk Fusion 360

• Integrated CAD/CAM/CAE software with robust modeling tools
• Cloud-based with real-time collaboration features
• Reasonably priced with free options for students and startups
• Extensive library of add-ons and plugins
• Direct integration with many manufacturing processes
• Steeper learning curve compared to more basic software

FreeCAD

• Free and open-source parametric CAD software
• Supports solid modeling, mesh shapes, and 2D sketching
• Provides a robot simulation module for motion planning
• More basic functionality and interface compared to premium tools
• Extensible through community-developed plugins and workbenches
• Shallower learning curve and well-suited for beginners

SolidWorks

• Powerful parametric CAD software geared towards professionals
• Extensive modeling, simulation, visualization, and CAM tools
• Plugin ecosystem and partner products for electronics and IoT
• Built-in PDM tools for version control and collaboration
• Higher price point and steeper learning curve
• Trusted and widely used in professional environments

Siemens NX

• High-end CAD/CAM/CAE software for complex designs
• Synchronous technology for easier model changes
• Mechatronics concept designer for robot and machine design
• Integrates with many simulation and manufacturing tools
• Expensive and geared towards large enterprises
• Very powerful but also complex and harder to learn

Here’s a quick comparison table of these top chassis design software options:

Tips for Designing Better Robot Chassis

As you dive into chassis design, keep these tips and best practices in mind:

1. Keep it simple – Avoid overly complex designs when possible
2. Design for manufacturing – Consider how parts will be fabricated
3. Use off-the-shelf components – Save time and money when practical
4. Allow for adjustability – Make it easy to tweak and modify the chassis
5. Consider wiring and cable routing – Leave space for tidy cable runs
6. Don’t neglect aesthetics – A little styling goes a long way
7. Document as you go – Don’t wait until the end to create drawings and instructions
8. Validate each design change – Virtually and physically test each design iteration

Chassis Design Software FAQs

What’s the best software for beginners to design robot chassis?

FreeCAD is an excellent choice for beginners looking to design basic robot chassis. It’s free, has a relatively shallow learning curve, and provides all the essential modeling tools you need to get started.

Autodesk Fusion 360 is also a great option if you’re willing to spend some money. It has a more modern, intuitive interface and extensive learning resources available.

How much does professional robot chassis design software cost?

High-end packages like SolidWorks and Siemens NX can cost over $10,000 per license, plus annual maintenance fees. These packages are geared towards professional engineers and large enterprises.

More affordable professional-grade options like Autodesk Fusion 360 are available for around $500/year. Free packages like FreeCAD are suitable for many robot projects and smaller businesses.

What software do professional robotics engineers use?

Many professional robotics engineers use SolidWorks due to its powerful modeling and simulation capabilities, large user community, and widespread industry adoption.

Other popular choices include Autodesk Inventor, Siemens NX, CATIA, and Creo. The choice often depends on the specific industry and existing software infrastructure.

Do I need a powerful computer to run chassis design software?

While entry-level packages like FreeCAD can run on most modern PCs, professional CAD software generally requires a high-end workstation to run optimally.

Look for computers with fast CPUs, plenty of RAM (32GB+), dedicated graphics cards, and SSD storage. A large, high-resolution monitor is also recommended. Gaming laptops can be suitable for mobile CAD work.

What’s the best way to learn robot chassis design software?

Start by choosing a package that matches your budget, skills, and project requirements. Then, focus on learning the tools and workflows specific to robot chassis design.

Most CAD software includes built-in tutorials and example projects to help you learn the basics. Supplement this with online video courses, user forums, and documentation.

Practice by designing basic chassis and incrementally working up to more complex designs. Recreating existing chassis designs is a great way to hone your skills.

Conclusion

Designing a high-performance robot chassis is essential for any successful robotics project. Using the right CAD software can make the design process faster, easier, and more accurate.

We’ve covered the key features to look for in chassis design software, including 3D modeling tools, usability, compatibility, collaboration, and cost. We also walked through a typical chassis design workflow and compared some of the top CAD software options.

By leveraging these tools and following best practices, you’ll be well on your way to designing better robot chassis for your projects. Remember to start simple, iterate often, and validate each design change.

With the right software and approach, you can create custom robot chassis that are optimized for your exact requirements and constraints. Happy designing!