Rapid Prototyping for Embedded Systems

Question

For doing prototyping on small embedded projects that require physical motion, what hardware prototyping tools are available? For my projects, I tend to spend more time finding parts (i.e. wood, aluminum, etc.) and making the proper cuts, measurements, and connections than writing the software and configuring the electrical hardware.

Are there any affordable products that will enable me to create physical hardware that is strong enough to support motion? If not, what techniques or tools are available to help develop the physical hardware more quickly?

Currently, I typically build my projects from wood and plastic scraps that I have lying around. What types of materials enable you to prototype more quickly?

CLARIFICATION: By motion, I mean something that has to bear stress like a robot arm powered by a servo motor and could handle moving or carrying 1-2 lbs.

Answer 1

If you're doing this professionally, and not as a hobby, I suggest structural aluminum extrusions.

These extrusions are pretty strong, and feature well-defined dimensions which make it easy to build with them. Moreover, various simple and complex hardware and accessories are available -- from brackets and hinges to pulleys and roller bearings. In some cases, the inner chamber of the extrusions can also act as plumbing channels for distributing pressurized air (or just routing cables within them).

McMaster Carr has plenty of "80/20" brand structural aluminum bars and mating hardware in stock, although they are a bit pricey. There are other companies (Bosch, for one comes to mind) - but it seems like 80/20 has a really good distribution network in the U.S. 8020 call themselves "The Industrial Erector Set" -- that's a pretty good description of what they are.

See www.8020.net

Now, if your definition of "affordable" means getting the raw material on the cheap, you might want to consider using standard plumbing pipes and fittings. You can cut pipes to length and use pipe threaders to thread the pipes. You can bend pipes and use various N-way fittings.

Answer 2

If you're doing something small and it's a hobby, there's always Lego Technics :)

Answer 3

80/20++

Or buy a toy/RC robot arm and replace the electronics with your own.

Answer 4

As a hobby there is always the good old Erector Set

http://en.wikipedia.org/wiki/Erector_Set

Answer 5

Here are some links to a few websites that provide products for building robot chassis and robotic arms, etc. The Vex products were used in the First Robotics Competition and now have been replaced with the TETRIX parts. You might also, be interested in the Servo Erector Set parts over at Lynxmotion for creating robotic arms.

Vex Structure Products
TETRIX Parts
Servo Erector Set

Answer 6

An attempt at a taxonomy of physical prototyping materials, and a list of the various prototyping materials available, is at RepRap: Frame material.

Is there some way to objectively compare these prototyping materials? The "CNC machines built from that material" in the above list is the closest thing to a "benchmark test" I've seen for physical prototyping materials, but it still falls far short of what I'm used to in CPU benchmarking.

Some of the systems listed there you might find useful:

• the Contraptor "open source construction set"
• MakerBeam "an open-source metal building system ... miniature T-slot"
• the "grid beam" "open source" system