Solving satellite deterioration with remote repair arm

For this project I was hired by a space technology start up to bring to life their robotic arm concept. They were aiming for a small 3D printed robotic arm that can automatically repair broken satellites.

I started designing this arm first by looking at open source and pre-existing work for robotic arms. I studied how the joints were created, how the motors interfaced with the proceeding segment and how the electronics was wired. The main requirements were it needed to have 6 DOF, have a 3 prong gripper and fit in a 175mm cube. Our goal was to start with a 3D printed arm, assembled with primarily off the shelf components.

The first challenge of this robotic arm was finding small motors that had enough power to lift each subsequent segment. After mocking up the arm and estimating its mass I ran torque calculations to ensure the motors were strong enough. I then designed each segment (with bearings, gaskets and braces) to ensure a robust design. After the initial design was tested we realized the next big feat was going to be wire management. I worked with other engineers to brainstorm a strategy that involved a homemade slip ring. This slip ring would allow seamless power transfer between joints while allowing full range of motion with no limits. I designed the slip ring in Eagle using pogo pins and thin traces to ensure a constant connection and small profile.

During this process I worked with another engineer who was in charge of manufacturing and assembling the arm. We had to work closely together to ensure a smooth production pipeline. I also worked closely with the CEO of Infinte Space Technologies who helped lead us through this process.

The other engineers and I were able to develop, manufacture, assemble and test this robotic arm concept. The CEO of the company took this initial concept and went on to search for research and venture funding for growing the company.