Innovative Design and Development of PANDORA: Advancing Humanoid Robotics Through Additive Manufacturing

This dissertation presents the innovative design and development of PANDORA, a full-sized humanoid robot that stands 1.9 meters tall and weighs 45 kilograms. Its highly configurable structure was created primarily using Additive Manufacturing(AM) techniques. PANDORA is designed to address the limitations of existing humanoid robots, particularly regarding accessibility, cost, and customization for research purposes. The robot features 32 degrees of freedom, enabling it to perform a wide range of human-like motions, such as walking, reaching, and manipulating objects.

The development of PANDORA focuses on leveraging the flexibility of AM to create a lightweight, cost-effective, and easily modifiable robotic platform. The dissertation details the iterative design process, which includes the structural components for weight reduction while maintaining the necessary strength and durability for dynamic movements. The lower body of PANDORA incorporates advanced joint configurations and custom-designed linear actuators, initially developed for previous Terrestrial Robotics and Engineering Controls (TREC) Lab robots, such as THOR and ESCHER. The upper body features a cable-driven arm system, which is both lightweight and highly functional, offering eight degrees of freedom per arm.

A significant contribution of this work is the development of design heuristics for AM, tailored specifically for the construction of large-scale robotic components. These heuristics were validated through extensive finite element analysis (FEA) and physical testing, ensuring the AM parts could withstand the loads and stresses encountered during operation. The open-source nature of the PANDORA platform, including all design files and documentation, further enhances its value to the research community, providing a robust foundation for future developments in humanoid robotics.