Weekly Assignments Final Project About me

Table of Contents

Objectives Timeline Individual Assignment
  • Conclusion
  • References
  • Design Files

    • 17. Applications & Implications, Project Development

    Objectives

    Timeline

    Individual Assignment

    Applications & Implications

    • Propose a final project masterpiece that integrates the range of units covered, answering:

      • What will it do?

        It is a toy robot that resembles a TV on legs. It can:

        1. show at least 2 animated expressions on the screen; happy and neutral idle animation that are accompanied by corresponding sound effects
        2. It can shuffle around in a movement that resembles dancing.
        3. It reacts to user proximity, dancing only when the user is far away. When the user comes close to the robot, it stops shufflng and stands still, making it look like a regular TV on a stand
        4. It powers ON and OFF based on voice commands

      • Who's done what beforehand?

        I will be using the following assets/files made by others to make my final project:

        • I will be using a custom Arduino library called FluxGarage RoboEyes Libraryfor the facial expressions
        • The design of the legs that create the shuffle/dance are based off of an open source project calledOtto
        • For the CRT TV, I will be using image references to build the 'head' of my project

      • What will you design?

        CAD design of the whole body, the PCB design, programming

      • What materials and components will be used? Where will come from? How much will they cost?

        All these questions have been answered in my tentative BOM sheet

      • What parts and systems will be made?

      • What processes will be used?

        I have used the following processes:

        • 3D printing - for making the outer body
        • PCB Designing - in KiCAD
        • Milling - To make the PCB
        • Soldering - To make the PCB
        • Programming - In Arduino IDE & VS Code

      • What questions need to be answered?

      • How will it be evaluated?

      • Your project should incorporate:

        • 2D and 3D design ✔
        • additive and subtractive fabrication processes ✔
        • electronics design and production ✔
        • embedded microcontroller interfacing and programming ✔
        • system integration and packaging

      • Where possible, you should make rather than buy the parts of your project

      • Projects can be separate or joint, but need to show individual mastery of the skills, and be independently operable

    Project Development

    Project Schedule

    I used the help of ChatGPT to be able to produce the the project plan given below. The ChatGPT prompts are given here

    Spiral Dates Focus Objectives Risk Analysis Deliverables
    Spiral 1 April 12–19 Input Sensing & Cardboard Prototype
    • Build a cardboard prototype to finalize design, input (INMP 441), output (OLED), and proximity sensor
    • Cardboard structure durability
    • Sensor range and accuracy
    • OLED compatibility
    • Cardboard prototype with voice-controlled ON/OFF
    • Head rotation via proximity sensor
    Spiral 2 April 20–26 Voice Commands & Basic Emotion Display
    • Program voice input to toggle ON/OFF
    • Display basic happy/sad faces on OLED
    • Voice recognition accuracy
    • OLED display functionality
    • Reliable ON/OFF voice control
    • Static happy/sad faces on OLED
    Spiral 3 April 27–May 3 Head Rotation Based on Proximity
    • Integrate proximity sensor to rotate head toward user when ON
    • Smoothness of head rotation
    • Sensor responsiveness
    • Servo-controlled head rotation via proximity sensor
    Spiral 4 May 4–10 Finalizing Structure & Electronics
    • Finalize housing (cardboard or laser-cut/3D printed)
    • Integrate servos, voice input, and OLED into structure
    • Fit and durability of housing parts
    • Secure wiring and component placement
    • Final integrated prototype with head rotation, voice control, OLED
    Spiral 5 May 11–17 System Integration & Testing
    • Integrate all components into one system
    • Test full functionality: voice ON/OFF, head rotation, expression change
    • Component integration issues
    • Power consumption and stability
    • Fully functional Lumi with core features
    Spiral 6 May 18–24 Documentation & Final Presentation
    • Document all steps and create demo video
    • Prepare final presentation (slides/website)
    • Clarity and completeness of documentation
    • Technical reliability of demo
    • Final presentation materials
    • 1‑minute demo video
    • Complete project documentation
    ChatGPT Prompt 2: Cardboard to A TV on Legs Plan

    Prompt 2: Cardboard to A TV on Legs Plan

    Here is a simplified version of your Lumi project goal and scope, framed as a week-by-week spiral development plan from cardboard prototype to the final model (“A TV on legs”):

    Summary Objective

    Lumi is a robotic pet with an expressive OLED face that responds to voice commands, rotates to face the user, and stands on foldable legs.

    Phased Approach from Cardboard to Completion

    Phase Focus Tools/Processes Expected Outcome
    Phase 1 Cardboard Prototype
    • Laser cutting cardboard parts
    • OLED + INMP441 basic setup
    		 Physical form + Input/Output basics tested
    Phase 2 OLED Head + Emotion Display
    • FluxGarage eye graphics
    • Facial expression coding
    		 Robot with animated face display
    Phase 3 Voice Input and Bluetooth
    • INMP441 for voice trigger
    • BLE commands (mobile app or serial)
    		 Lumi responds to voice/Bluetooth
    Phase 4 Movement System
    • Design folding leg mechanism
    • Test with servos or micro actuators
    		 Folding/Standing motion works
    Phase 5 Full Integration
    • Package OLED, sensors, body
    • Final polish and bug fixing
    		 “TV on legs” working robot pet!
    ChatGPT Prompt 3: Essential vs Optional Features

    Prompt 3: Which features are essential and which are optional?

    Below is a breakdown of the essential vs optional features in your Lumi project:

    Essential Features (Core to Graduation Requirements)

    • Voice Input — Lumi should respond to basic voice commands like “Turn ON” and “Turn OFF”.
    • OLED Facial Expression Display — Display emotional states like happy or curious using SSD1306.
    • Proximity Sensing — Lumi should rotate to face the user when ON.
    • Cardboard Body Prototype — Demonstrates 2D design and subtractive fabrication (laser cutting).
    • 3D Printed or Fabricated Parts — E.g., motor mounts, shell, ears (satisfies 3D design and additive fabrication).
    • Electronics Design + Programming — Integration of sensors, display, and MCU with embedded code.
    • System Integration — All subsystems working together (input, display, movement).

    Optional Features (Nice-to-Have Enhancements)

    • Real-time Time/Weather Updates — Voice-triggered info system like Alexa.
    • Animated Servo Ears — Reactive ear movements synced with voice or emotion.
    • Foldable Servo Legs — Adds complexity; can be simplified to static legs for MVP.
    • Self-Balancing with IMU — Challenging; optional unless core to your story.
    • Bluetooth Control via Remote — Optional unless used to replace unreliable voice input.

    Recommendation

    Focus on completing all essential features first, especially those linked directly to Fab Academy criteria. Then, expand based on time and technical confidence.

    ChatGPT Prompt 4: What is the minimum I need to do to graduate?

    Prompt 4: What is the minimum I need to do to graduate?

    To meet Fab Academy’s graduation requirements, your Lumi project should include the following:

    ✅ Minimum Graduation Criteria

    • 2D Design + Subtractive Fabrication: Laser-cut cardboard or acrylic for the robot's body and parts.
    • 3D Design + Additive Fabrication: 3D print small parts like motor mounts or ears.
    • Electronics Production: Use or modify a custom PCB with mic input + OLED display.
    • Embedded Microcontroller Programming: Code that listens to voice commands and displays expressions.
    • Input Device: At least one (e.g., INMP441 mic or proximity sensor).
    • Output Device: At least one (e.g., SSD1306 OLED screen).
    • System Integration + Packaging: Everything should work together in a well-packaged design.

    📌 Summary

    Focus on a basic working prototype with voice input, OLED expressions, rotation using proximity, and neat packaging using digital fabrication. Everything beyond that is optional polish.

    ChatGPT Prompt 5: Make my project simpler

    Prompt 5: Make my project simpler

    Here’s a simplified version of Lumi that still meets all graduation criteria:

    🎯 Simplified Lumi Features

    • Voice Control: Recognizes “Turn ON” and “Turn OFF”.
    • OLED Face: Shows two expressions – happy & curious.
    • Proximity Sensor: Turns head to face you.
    • Laser Cut Body: Simple folded design, housing display + sensors.
    • 3D Printed Ears or Sensor Mounts: Tiny 3D part for showcase.
    • Minimal PCB + Microcontroller: INMP441 mic + SSD1306 OLED + servo.

    🛠 Technologies Used

    • 2D & 3D Design
    • Additive + Subtractive Fabrication
    • Embedded Programming (microcontroller)
    • Electronics Design (basic PCB)
    • System Integration

    This version is much more achievable while still allowing you to expand with ears, IMU, or weather updates later.

    ChatGPT Prompt 6: Why does this project exist?

    Prompt 6: Why does this project exist?

    This project exists to explore how machines can interact with humans in an emotional and engaging way. Lumi bridges the gap between technology and empathy by mimicking simple pet-like interactions using expressive eyes, voice input, and responsive behavior.

    ChatGPT Prompt 7: Modify to increase clarity

    Prompt 7: Modify this statement to increase clarity: "To create a machine that can interact in a human-like manner with empathy."

    Clearer Version: To create a robot that interacts in a friendly, human-like way and makes people feel understood or cared for.

    ChatGPT Prompt 8: A machine that can evoke human empathy

    Prompt 8: A machine that can evoke human empathy (simplified)

    Simplified: A robot that makes people feel emotions, like they would with a pet or friend.

    ChatGPT Prompt 9: Robo pet for people who can’t keep real pets

    Prompt 9: A robo pet for people who can’t keep real pets

    A robotic pet made for people who don’t have time, space, or resources to care for a living animal.

    ChatGPT Prompt 10: A TV on legs

    Prompt 10: A TV on legs

    This playful description captures Lumi’s personality — a robotic creature with a screen that displays expressions and moves like a living being.

    Lasercutting a Mockup in Cardboard

    08-05-2025: I lasercut a mockup design of my final project.

    Testing TFT display

    09-05-2025: Testing refresh rate of LCD screen to play animations and video footage

    Sketching an Exploded View

    10-05-2025: Updated a sketch showing an exploded view of of my final project and how each compenent will be integrated

    CAD Model

    I made a finalised CAD model of my design that integrates all the electronics. To do this I first arranged all the electronics placement, then went to KiCAD if connections can be made in the desired arrangement, make minor changes, then reintegrate thos changes in the CAD model

    PCB Design

    I designed two PCBs, the bigger 'mount' PCB that holds the front facing electronics; the LCD display and the switches, along with the battery on the back side. On this PCB, I stacked another doublesided PCB that holds all the internal electronics; including the microcontroller, the buck converter, the amplifer, along with the USB port and the micro SD card reader

    I used this schematic that connected the microSD card directly to their microcontroller. I adapted this for my Use

    Question: Will the SD card work without pullup resistors between MOSI, MISO and SCK connections.

    After I arranged all the components in Fusion, I projected a sketch of placements into KiCAD and used that as a reference to make my final PCB design, Due to pads and spaces for traces, the design will be slightly modified from original. Once my mount PCB design was done, I exported a CAD model back into Fusion, projected all reference geometries including from the battery, 2x3 pin headers, JST connectors and screw holes and edge cut of mount PCB into a new sketch that I exported as a DXF that I brought once again into KiCAD to repeat the steps.

    To make sure I align the male pins and female sockets of both PCBs, I copy and paste PCB layout from PCB mount and line it up on top of my DXF sketch. I then delete all the components apart from the pin sockets and lock it to prevent it from being removed when I update the design. Then I manualluy adjusted the position of the headers by looking at the 3D view to get the best possible alignment. Since the pads are long enough, minor adjustments can be made as long as the header is nearly on top of the sockets

    I then modified the Audio Amplifer Pads to be an SMD type

    Since I did not find any datasheet for the BEC buck converter except external dimensions, I made an educated guess that since the module mostly likely uses 2.54 mm pitch header pins, the spacing of the holes will also be the same as other components like header pins.

    Conclusion

    Notes for the Future

  • How to replicate PCB layouts in KiCAD
  • Using design blocks in KiCAD
  • Design multiple PCBs in KiCAD
  • Projecting pads and importing DXF does not help with aligning header pins and socket pins

    • Add Mistakes only in Mistakes and Solutions section to avoid break in flow

    References

    References to help reader understand in detail

    Look at previous year documentation

    Design Files

    Click here to access the project files