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Robocop ED-209 by RandomDesign

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 Hey its RandomDesign,

finally CMWS is back.

Lets first have a look at the hardware that should be used for the project:

Motherboard: MSI MPG-B650I-EDGE-WIFI
CPU: AMD Ryzen 9 7950X3D
GPU: MSI Geforce RTX4070 Super 12G Ventus 2x White OC
Memory: Trident Z5 Neo RGB DDR5-6000
PSU: Cooler Master V850 SFX Gold

Water cooling: Alphacool



The concept:

For this years competition, I am planning to build a version of the ED-209 robot from the movie Robocop.
Most of the hardware and watercooling components will be placed in the head section.
By doing that, the hardware should be included into the design as if it is one part of the construction
and might fit a specific purpose.
I will also try to include some LED effects and moving components to match the design of the original as close as possible.

Many parts will be 3D printed, but most of the parts that I need multiple times, will be mold in silicone and then cast in a urethan resin.
I am also going to use a cold cast technique with real metal powder to create all the metal looking parts.
Detailed descriptions will follow as soon as that parts will be created.

Now lets see the original design. I got some images from the latest Robocop game, directly from the publisher Nacon.
Its a good starting point to get high resolution images of the machine, as it has not changed from the one used in the movie.







I used this images to create my own 3D model to get not only all the parts for 3D printing, but also a good reference on size
and where all the hardware components should be placed.
It also helps to get a better idea on how I want each part to be fit together and how a stabilizing core construction can be included.
In total the entire 3D model has about 209 individual parts that need to be fabricated, post processed and assembled.





And of course some final renderings of the 3D model









Edited by RandomDesign
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  • 1 month later...

To make it easier to follow my progress, I will always mark the areas in the 3D model I am currently working on.

Starting at the bottom, the first part to work on was the feet section.




The middel construction of the feet is 3D printed in PLA. I already included all the holes necessary for mounting them later to a base and for
the stabalizing aluminum core.






Cause I need all the "toe" caps multiple times, they will be mold and cast in a urethan resin.
The templates were first resin printed to make the post processing a little easier and faster.






Then all parts for the feet were 3D printed and ready for post processing. You can also already see parts of the inner leg construction.


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  • 3 weeks later...
Posted (edited)

The advantage of the resin printed toe parts is the easy post processing compared to PLA.
Just took some 280 grid sandpaper followed by 400 grid wetsanding to prepare the part for the next step.




Cause I need each piece of the toes at least two times, and I wanted to make them a bit more sturdy, I decided to not use the resin print.
Instead I am going to cast all the parts in a urethan resin. That way they wont be as brittle as the resin print.
Unfortunately, I missed taking pictures of the mold making process for this piece, but I will come back to the technique later in more detail.
For the molds , I used Mold Star 30 from Smooth On.




To save material and weight, the parts were rotocast. I just filled some resin into the mold and than rotated it until the resin was set. 




Here is one test piece I made to see if the thickness of the wall was enough. In total, I made five pours of the urethan resin to slowly build up to the desired thickness.





To further stabilize the part, but not add unnecessary weight, the parts were filled with an expanding foam.




Looking good so far.



Edited by RandomDesign
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  • 2 weeks later...

The next part is the the main section of the lower leg.




This section is a combination between an inner core that will be responsible for the stability and an outer shell.
The inside parts are already equipped with holes for the aluminum profile and the metal rods that will hold everything together.




For stabilizing i will use a 20x20 mm aluminum profile and some 6 mm threaded rods.








To fit the outer shell on my 3d printers and have a good orientation, I needed to split it into different sections.
Next up is the post processing on those parts.


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  • 2 weeks later...

After all parts for the next section were printed, I started by sanding them down with 120 grid sandpaper.







Afterwards, all the parts were assembled. I just used super glue, that will be more then enough to hold all pieces together.





And of course I made a first test fit with all the other parts of the leg that I have done so far.




Next up, I need to start and fill in all the gaps and imperfections. Will show that process in the next post.

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