After getting off to a rapid start my Dieselpunk inspired crawler ground to a standstill while I waited for parts, now that they have arrived everything is up and running. Sometimes when the design and printing go well they are the quickest part of the project!
All of the parts fit in the RoboxDual, you can find them here for download. I printed the vast majority of the project in ABS, but PETG will do just as well.
Since sculpting is not my strong suite I called in the assistance of my talented friend Fotis Mint who was kind enough to model a cool head for the driver. There is nothing quite like 3D printing and the internet to make a collaboration across thousands of miles seem like you are working in the same studio.
From the perspective of design for printing however the most interesting part of the project are probably the various arm joints on the driver figure. I needed a lot of freedom of movement, so that the steering wheel servo could make the arms move, without putting much strain on it. I also wanted to avoid fiddly assembly and printing with supports, so I came up with a three piece design that results in 5 axes of movement. Two of the joints are simple pivots using 1.75mm filament off-cuts as hings, but the others print in place, as shown below. These are the sorts of things that would be impossible to do with other manufacturing methods.
The assembly of these joints can be seen at the 7 minute mark of the video below.