3D Printing

Desktop 3D printer

3D printers produce plastic parts under computer control. The process of 3D printing is especially useful for the smaller insect-class bots, where weight is a severe limitation to design. However, even Heavyweight-class builders use 3D printing to make composite reinforced components, custom compartment insulators, and wire guides. Keeping electrical parts and cables away from metal plates and sharp edges reduces the risk of damage and short circuits.

3D Printing is widely used in one specialized division of combat robotics, the Plastic Ants class, where the chassis and weapons (if any) must be made of plastic in order to qualify.

If you don't own a 3D printer, you may be able to get help from your local library or makerspace, or from your fellow bot-builders. Some people will want to design their own bots, which requires knowledge of 3D modeling using a computer or app for the purpose. Others will choose to download a premade design (see below). Once you've got a bot design working to your satisfaction, you can print a supply of replacement plastic parts, which can be used for repairs after your bot becomes damaged.

Selecting a Printer

Selecting a printer for 3D printing a combat robot can be a big decision, and here are some factors to think about when purchasing your printer.

Budget

Desktop and office 3D Printers can range from as low as $150 to over $10,000 depending on their hardware, capabilities, build volume, and other factors. Here's a quick overview of what's available:

• Budget-friendly/hobbyist 3D printers: Range from $150 - $750, normally limited in materials and build volume. These include machines like the Creality Ender 3 series, and will normally have a maximum nozzle temperature of 245-250° Celsius. These machines are meant for printing PLA, PETG, and ABS, but by replacing or modifying some components, they can print more advanced materials like Nylon and TPU.

Note: Some low-end crafting printers don't have a heated printing surface. These should be avoided, since they don't work with a variety of plastics.

• Advanced materials printers: Range from $750 - $3,000, and are capable of printing materials like PLA, ABS, PETG, TPU and other flexible types, Nylon and nylon composites, and Polycarbonate blends with minimal or no aftermarket modifications. These will have a maximum nozzle temperature around 295-300° Celsius and can heat their print surface to 100° Celsius or more.

Better advanced printers have an enclosed print area to keep the temperature of the part consistent during printing. There are printable kits to enclose standard open-frame printers.

• Engineering grade printers: These range from $3,000 - $10,000+, with few materials outside of their capabilities. These printers are often able to print not only advanced materials but also multiple materials using multiple extruders or multiple tool heads, allowing for even greater complexity. Multi-extrusion can allow for printing multi-color items (e.g. black and white), multi-material items (such as mixed PLA and PETG), or soluble support materials like PVA/BCOH.

Printable Filaments and Materials

The materials that a FDM (Fused Deposition Modeling[1]) 3D printer can extrude must melt at a given temperature, maintain a consistent flow of material through the nozzle, and solidify in a consistent fashion. These materials include thermoplastics, waxes, and even chocolate! With specialized printers it is possible to use such materials as ceramics, glass, and concrete.

Most 3D prints in combat robotics will be made from rolls of plastics and plastic composites on an FDM printer. "Resin" printers are becoming more common in larger sizes at budget-friendly prices, and more options for resins are available to purchase on a regular basis.

The list of common 3D printable plastics below proceeds roughly from weakest to strongest.

PLA

PLA is inexpensive, but brittle.[2] It is the most common 3D printing filament. It rarely warps in use and is great for tiny parts.[3] It's a great starter material, and recommended for printing prototype parts. Many builders prefer other plastics, especially for their active weapons or armor. Pure PLA is made from cornstarch[4] and gives off a corn syrup odor which reminds some people of waffles.

PLA+

Various manufacturers offer "PLA+" and/or "Tough PLA," which are modified PLA filaments that are meant to be less brittle. With an acrylic additive, for instance, it may show much better impact resistance.[5] Inland and eSun claim their PLA+ products are 10x stronger than regular PLA.

PETG

PETG (a copolyester) is more heat resistant, more flexible, and less brittle than PLA.[6] It is well suited for 3D printing mechanical parts. Since it is more likely to flex under impact its resilience may be useful to the bot builder, but it is 2-3% heavier than PLA. Observe manufacturer's recommendations when printing, as it tends to stick very strongly to smooth print beds. You'll notice a fairly mild hot-plastic odor when printing.

ABS

ABS is a strong and reasonably impact-resistant material at a moderate price, but warps easily and smells worse while printing. Its low density makes it one of the lightest of all printable plastics (PLA is about 20% heavier for the exact same print). You'll probably need to print it in an enclosure for best results; this keeps its temperature even during printing, so that it only shrinks after printing instead of curling or warping during printing. Many hobbyists ventilate the enclosure to the outdoors with fan(s) due to the odor.

Nylon

Nylon is tough and flexible. Regular nylon is hygroscopic and must be kept in dry storage, or it will absorb moisture from the air and become spoiled after a few weeks. Consider buying a hybrid nylon material that doesn't require as much attention to storage.

PC

Polycarbonate is super strong - your robot arena walls are probably made from it! Many printers can't print it, though, because it must be heated to an extreme temperature (about 275°C/525°F).

CF Materials

Carbon-fiber reinforced materials are extremely tough, and ideal for combat robotics. These are usually polycarbonate or nylon with chopped fibers embedded inside. You should strongly consider using these when plastic parts are needed for beetleweight designs.[7] This material requires a hardened printing nozzle, as the carbon-fiber strands or particles are highly abrasive.

Tips and Best Practices

• Nearly all 3D printers can handle PLA and PLA+. Most other materials require printing onto a heated surface (the "print bed"). Check the specifications and instructions of your printer to find out what materials it can handle.
• A basic limitation of 3D printed parts is that they can crack or break apart along layer lines, since they are made from layers of plastic. Generally, the tougher the plastic the more likely the layers will also hold together.
• Pay attention to the orientation of parts on the print bed - consider orienting parts so that the direction that needs to be the strongest lies horizontal during printing.
• You can make adjustments each time you print. Thicker walls (shells) and a higher percentage of infill add density and strength to your bot, but also increase weight. Remember to re-weigh your bot after changes have been made.

Robots you can Print

You can download and print robot designs from sites like Thingiverse and Prusaprinters. Just 3D print the robot body and other provided parts, then assemble them with the working parts of the robot. Some have helpful instructions and buying suggestions for finishing the working parts; however, some have little or no guidance, and you will need some experience to try them.

Below are links to 120 bot designs that have been shared by the robot building community. Limited consideration has been given to whether each of these is buildable, or will meet the stated weight class.

150g Combat Robots

Bot	Class	Type	Provided by	ID #	Notes
(Unnamed)	150g	4WD Pusher	ACE_ROBOTICS	3022477
(Unnamed)	150g	Flipper	emancarrillo	3186849
(Unnamed)	150g	Hammer	emancarrillo	3811105
(Unnamed)	150g	Horizontal spinner	emancarrillo	4094199
(Unnamed)	150g	Lifter	Flaronk	2435280
(Unnamed)	150g	Flipper	JairEmia	4743535	N20 powered
(Unnamed)	150g	Hammer or Flipper	JairEmia	4901799	N20 powered
(Unnamed)	150g	Pusher	beardedowen	2103348
(Unnamed)	150g	Hammer	Tom_Dreyfus	3906492	Remixed
(Unnamed)	150g	Suplex bot	emancarillo	4627536
(Unnamed)	150g	Wedge	Technick007	4330363
(Unnamed)	150g	Plow	Jhack	2954423	Dozer with tracks
3D Amazon Depot	150g	Horizontal spinner	Drcameron	3168988
A Bit Pushy	150g	Pusher	FalconFPV	3204827
Absolutely Quackers	150g	Hammer	Team_Panic	3341786	Hammer duck
ACE	150g	Lifter	ACE_ROBOTICS	3022464
Additions for Unnamed	150g	Flipper	AlexKorvin	3933072	Based on 3186849
Afterlife	150g	Wedge	johnszy	3234339
Aionia Timoria	150g	Drum spinner	drcameron	3168573
A Little Obvious	150g	Angled spinner	Team_Panic	3431621
Ant Freeze V2	150g	Wedge	Zanbots	3815539
Baby Shark	150g	Wedge	thesaxmachine	3810730
Barq's Bites	150g	Flipper	drcameron	2998633
Big Flip	150g	Plow	SiegelRacing	4616666
Big Sup	150g	Suplex bot	SiegelRacing	4693024
Blackspin	150g	Drum spinner	JC2017	2805613
Black Star	150g	Wedge	Ajaxjones	2065860
Blind Spot	150g	Dustpan bot	Team_Panic	3341761
Blockhead	150g	Drum spinner	earthwormjim	2812197	Large beater bar
Bulldog	150g	Vertical spinner	Bribro12	4623536
Brutus	150g	Drum spinner	AlexKorvin	3972258	Overweight (see link)
Brutus Remix	150g	Drum spinner	cannon3d	4182360
Brutus Mk2	150g	Horizontal spinner	AlexKorvin	4338982
Crabulon	150g	Shufflebot	Drogg	3195078
Drum Battlebot	150g	Drum spinner	emancarrillo	5240385
Dynamo	150g	Wedge	Pyrotron	1215069
Entomat	150g	Flipper	GermanRoboteersAssociation	5150517
escoBAR	150g	Horizontal spinner	ninja_drift	3752142	based on Shrapnel
Firestorm 125%	150g	Flipper	FalconFPV	3039761	32mm wheel/N20 version
Firestorm Micro	150g	Flipper	AdamDC	2927678	N20 version
Firestorm (Original)	150g	Flipper	alexmordue	1665299
Flowers	150g	Shell spinner	SiegelRacing	4327093
Fork Fairy	150g	Wedge	JairEmia	5136959
Fork Wedge	150g	Battlebot	emancarillo	4216968	Overweight (see link)
Front Flip	150g	Flipper	Fryddog	4352090
Front Flipper	150g	Flipper	emancarrillo	4268191
Fury Jr v9	150g	Horizontal spinner	Dkero4	5351660
G1/Guestbot	150g	Pusher	Justgecko	4189961
Game Ogre	150g	Wedge	1337gallagher	4714362
Grabbybot	150g	Grabber/Lifter	emancarillo	4281243
Graboid	150g	Grabber	JC2017	3323762
Grabthar	150g	Modular (Multi)	Aldwin	4868890
Guestimate	150g	Horizontal spinner	Team_Panic	3707013
Gyrator	150g	Horizontal spinner	CNCROBOTICS	3070730
Gyrator v3	150g	Horizontal spinner	CNCROBOTICS	3164801
Halloween Pumpkin	150g	Pusher	NoLiver92
Hampire	150g	Thwackbot	Baker01t	5154492
Hello Trouble	150g	Bar spinner	Stonecreekturnings	4240015
HugsEy	150g	Grabber/Lifter	SiegelRacing	4325008
Inspired by Carbide	150g	Horizontal spinner	alexmordue	1816540
Kraken	150g	Crusher	emancarrillo	4308902
Legally Distinct	150g	Drum spinner	Blessy	5338319	V3
Loader	150g	Wedge	HarryMakesThings	2989490
LowMow	150g	Undercutter	JC2017	4866523
Luma’s Plow	150g	Flipper / Plow	LumakidT	5324201
Mega London	150g	Lifter	thesaxmachine	2945303
Microdot	150g	Triple wedge	Team_Panic	3341738
Microdot Updated	150g	Triple wedge	Team_Panic
Mini Emoji	150g	Lifter	ACE_ROBOTICS	3022469
Mini Mammoth	150g	Spin-Lifter	JairEmia	5318276
Netsplit	150g	Horizontal spinner	xanderstrike	4844195
Plover	150g	Wedge	aldwin	2022778
Rollcage	150g	Wedge	fryddog	1800795
Scoop of Mild Frustration	150g	Wedge, Plow	FiregirlRobotics	5176628
Scrapper	150g	Wedge	Fryddog	4297430
Servo Drive	150g	Hammer	WitchdoctorbyKO	4789416
Shrapnel	150g	Spinner	Fryddog	1692075
Shrapnel Mk3	150g	Spinner	Fryddog	3115202
Shredder	150g	Spinner	drcameron	3168636	based on Shrapnel
Siren	150g	Drum spinner	drcameron	3168700
Slightly Crude	150g	Wedge	Team_Panic	2054276
Spike	150g	Wedge	Fryddog	4311761
Spooky	150g	Horizontal spinner	BLRobotics27	3184758
Squeezy	150g	Grabber/Lifter	SiegelRacing	4567470
UnderScore	150g	Horizontal spinner	FalconFPV	3173115
UnderScore Remix	150g	Horizontal spinner	Printer239	5179359	Remix for 1806 motor
Upchuck	150g	Vertical spinner	FalconFPV	3099273
Vlad Micro	150g	Lifter	AdamDC	2927358
Wedge of Doom	150g	Wedge	FalconFPV	2946703
White Fang	150g	Horizontal spinner	Insertbattlebotsjokehere	3695273

All other weight classes

Bot	Class	Type	Provided by	ID #	Notes
(Unnamed)	1lb	Wedge	tbeg	2374705	Mk1
(Unnamed)	1lb	Vertical spinner	kkbittle	2036647
3DAD	1lb	Horizontal spinner	drcameron	3908901
4WD Wedge	1lb	Wedge	TeamLiftoff	4723564
Backlash	1lb	Horizontal spinner	clingmanr	3146568
Blockhead remix	1lb	Paddle spinner	shultiskevin	3111090
Blue Screen of Death	1lb	Horizontal spinner	chrismik	4075681
CheeseWej	1lb	Wedge	Teamd20	4885071	Plastic Ant
Danger Zone	1lb	Drum spinner	altapowderdog	766609
Doom Stone V1	1lb	Vertical spinner	kmcelroy	3297944	Plastic Ant
dropSAW	1lb	Vertical saw	ninja_drift	3768970	Chassis remix
Eureka	1lb	Wedge	Teamd20	4800332	Plastic Ant
FidgetBot	1lb	Horizontal spinner	billywoodworks	2513990
Fidget Stone	1lb	Horizontal spinner	Guggleshyena	3040924
Flapjack	1lb	Drum spinner	shultiskevin	3160354
Future Killer	1lb	Vertical drum	altapowderdog	3793747
Half-SMEEEEEEEEEEEE	1lb	Long split wedge	TheN00b	4675230
HUGElet	1lb	Vertical spinner	Crankymuffin	3188358
Ice Breaker	1lb	Drum spinner	SamDream	3175677	Plastic Ant
LifeSteal	1lb	Horizontal spinner	Posey	4910548	Plastic Ant
Little Slugger	1lb	Undercutter	Lord_Toby	5202939
Mega Looon V1	1lb	Vertical spinner	thesaxmachine
MI	1lb	Full-body spinner	RattlerRobotics	2828234
Mr. Roomba	1lb	Ring spinner	Kylellrc	3170974	Plastic Ant
Mr. Twister	1lb	Vertical spinner	AdamDC	1401358	Plastic Ant option. See also Alt blade
Plastique	1lb	Shell spinner	AdamDC	2813722
Simple Ant Weight Wedge	1lb	Wedge	mightygrom	3962507	Demobot
Tiger Shark V5	1lb	Horizontal spinner	thesaxmachine	3819420
Tiger Shark V6	1lb	Horizontal spinner	thesaxmachine
Tribute to Bite Force	1lb	Vertical spinner	Tom Lum		Plastic Ant
WejFu	1lb	Wedge	Teamd20	4843171	Plastic Ant
Mega Don G V2	3lb	Plow	thesaxmachine
Munchkin	3lb	Drum spinner	Creative_Instigation	3731962
Rapid Unscheduled Disassembly Mk6	3lb	Undercutter	TeamMagicalLipoFire	3179067
Vector	3lb	Horizontal spinner	Endbots	3917039
Vertex	3lb	Vertical spinner	Proxy303	4741317
Vertigo	3lb	Vertical spinner	Insertbattlebotsjokehere	4241833
Deadlift	1.5kg	Lifter	Noursicus	4232399
Plastic Donk	1.5kg	Wedge	Noursicus	4230265
Razor	1.5kg	Horizontal saw	AlexKorvin	5022333
Wall Chaser	1.5kg	Vertical saw	AlexKorvin	4967207
Mars Attacks (itself)	unknown	Shell spinner	shultiskevin	3160993
Combat Robot 2.0	unknown	Drum spinner	altapowderdog	1688510

Accessories you can Print

The following is a small selection of useful accessories for robot combat, most of which can be 3D printed. You might find robot parts that you need here, but this list is also a great starting point for design ideas and improvements for new bots as well.

Motors and Drive

• 22mm Planetary Gear Motor Mount for Beetleweight Combat Robots
• Brushless Adapter for 1103 Motor and N20 Gearbox
• Micro metal gear motor housing
• 16t fingertech pully 3.175mm shaft Belt pulley
• N20 motor bracket Three designs
• Double N20 motor mount
• N20 Gear Motor Shaft Bearing Reinforcement Protects N20 motor from radial loads such as side impact

Hubs and Wheels

• Fingertech/Liteflite Foam Wheel Hubs 3mm
• Lynxmotion Universal Hub 4mm (wheel hub)
• Antweight (150g) combat robot silicone wheels Hubs, wheels, and molds for making your own tires out of silicone. Cf. these videos.
• Comolded Silicone Wheels for 150g combat robot Newer version of the above.
• Combat Robot Wheel Hub Hubs for 2" foam wheels with 15mm diameter center.
• Banebot Wheel Hex Hub Substitute for Banebots aluminum hex hub with timing belt option for 4WD bots.
• Wheels for ant weight Battle Bot Wheels for use with foam strip material
• N20 wheel hub Hubs for cheap foam wheels
• Addons fuer Uncle und Co Wheels for SG90 servos
• Mechanum Wheels for 150g Robots
• N20 Motor - Lego Axle Adapts N20 D-shaft to drive Lego cross shaft wheels.
• 3mm D shaft hub Wheel Wheel for Lego #3483 tires
• Wheel 15mm D. x 6mm. 3mm D Axle Wheel for Lego #50861 tires 15mm D x 6mm
• 3mm D shaft hub Wheel Wheel for Lego #30285 tires 18mm D x 14mm

Electrical

• Combat Robot Power Switch
• Screw Power switch (low current 4-40 screw)
• Screw Power Switch (metric, M3 screw)

Weapons

• 2 tooth plastic ant blade
• Blade for Viper Kit from Fingertech Robotics Short blade for Viper spinner kit
• Slightly Larger Blade for ViperKit From Fingertech Robotics Longer blade for Viper spinner kit
• Disc for ComBot Vertical Spinners 50mm disc with 75mm teeth
• weapon bar 80mm & 60mm for 150gram combat robot
• 150g Antweight Axe Mechanism Geared arm for self-righting, axe, etc.

Arenas

• 6' x 6' Robot Combat Arena (trailer mounted)