Quadruped Robot Laelaps III

This project focused on the redesign and optimization of the mechanical foundation and drivetrain of Laelaps, a quadruped robot developed by the Legged Robots Team at the Control Systems Laboratory (CSL) of NTUA for dynamic locomotion and mobility research.

I led the mechanical design, analysis, and fabrication of both the chassis and transmission subsystems, targeting improvements in structural integrity, power transmission capability, and mass reduction.

Key Achievements:

• Lightweight Chassis Redesign
Reduced overall mass by 18% (from 39.3 kg to 32 kg), significantly improving agility and energy efficiency. The redesign also eliminated actuator–leg collisions, enabling the robot’s full range of motion.

• High-Torque Transmission Optimization
Re-engineered the leg transmission system, more than doubling output torque (hip: 38.6 Nm → 80.8 Nm; knee: 40.4 Nm → 80.8 Nm), greatly enhancing load capacity and control precision.

• Full-Cycle Prototyping
Managed the complete prototyping workflow — from 3D CAD modeling and CAM programming to CNC machining and assembly — integrating both in-house and outsourced manufacturing processes.

• Precision Manufacturing
CNC-machined 56 components across 10 unique part designs in-house, maintaining ±0.01 mm tolerances for precise assembly and consistent performance.
All sheet metal components were outsourced to external fabricators, with design and manufacturing specifications provided to ensure dimensional and functional accuracy.

• Quality Control
Performed dimensional inspections using calipers and micrometers to ensure accuracy and mechanical reliability across the chassis and transmission assemblies.