System Integration

Project Concept

For my final FabLab project, I am building a Battle Bot that brings together two worlds: the raw power of animals in nature and the sleek engineering of science fiction robots.

This robot is not just for show—it’s being designed to fight in real tournaments like the Technoxian WRC under the 15 kg weight category, where bots go head-to-head in intense matches. I want this bot to behave and move like a creature that’s built to survive — agile, precise, and brutal when needed.

The entire project includes:

Mechanical design and fabrication (body, weapon, armor)
Electronics integration (motors, control system, battery)
Remote control programming
Final system testing and performance evaluation

Design Philosophy – Inspired by Nature

Nature has already solved most of the problems we face in design — movement, attack, defense, balance. I took cues from:

Beetles: Strong armored shells, low and aggressive stance

Mantis shrimps: Lightning-fast strikes

Scorpions: Spinning tail stingers (which inspired the weapon design)

aim was to combine these ideas into a wedge-shaped bot that can glide low to the ground, push under enemies, and strike hard — all while protecting its internal brain and heart: the electronics.

Initial sketches

System Overview – How It Will Work

The robot will be controlled wirelessly using a mobile phone app connected to an ESP32 microcontroller. Two high-torque motors will drive the robot, and a separate motor will power the front-mounted attack weapon. Everything runs off a lightweight, powerful LiPo battery. The system includes a kill switch for emergency shutdown.

Here’s how the core flow works:

Mobile App sends input (via WiFi/Bluetooth) →
ESP32 receives input & triggers motors →
ESCs control motor direction and speed →
Weapon Motor + Drive Motors respond →
Power Distribution ensures safe battery use →
Kill Switch can instantly shut down all power in emergencies.

Electronics System – The Brain & Nerves

Electronics in this project are the core of control. It’s like the robot’s brain and nervous system — constantly processing, responding, and adapting.

Component	Function
ESP32	WiFi-based microcontroller to control everything
Blynk App	Mobile interface to send movement and weapon commands
DC Motors (x2)	For driving the robot (forward/backward/turning)
Motor for Weapon	Spins the blade or hammers the enemy
ESCs (x3)	One for each motor – controls speed & direction
3S LiPo Battery	Lightweight, powerful battery (11.1V)
Kill Switch	Emergency shutdown for safety
Wires & Connectors	Bullet plugs, heat-shrink wrap, solder joints, routing

Mechanical System – Skeleton, Muscles & Motion

Chassis Design:

The robot will have a compact rectangular frame with a low center of gravity to avoid flipping. The front is angled like a wedge to slide under opponents — just like beetles do in nature.

Frame Material: CNC-cut aluminum sheet with 3D-printed internal mounts
Size: ~300mm (L) × 300mm (W) × 100mm (H)
Weight Goal: Under 15 kg total

Drive System:

2 × DC Geared Motors with high torque
Wheels with rubber grip for floor control
Skid-steering control (one motor on each side)

Weapon Mechanism:

The bot’s primary weapon is a motor-driven rotating blade, inspired by mantis claws and spinning scorpion stings.

Weapon Design Ideas:

Circular saw blade (custom-cut)
Hammer spike (high-speed swing)
Modular mount so I can change weapon types

The weapon is front-mounted and triggered using a button in the app interface.

Attack & Defense System

Attack System: - Blade mounted low and center

Controlled via remote signal
Possible upgrade: auto-strike on obstacle detection

Defense System:

Polycarbonate panels to deflect attacks
Inner foam lining to absorb shock for electronics
Angled edges like armor plating to avoid direct hits
Rear bumpers for protection during turns

Packaging = Armor

In this bot, the packaging method is the armor itself.

Unlike a product box, here the outer casing needs to survive 5kg of kinetic energy crashing into it. So it’s not just packaging — it’s battle-grade shielding.

Armor Strategy:

Material: 3mm Laser-cut Polycarbonate (same used in bulletproof glass)
Frame: CNC-cut Aluminum base for rigidity
Mounts: 3D-printed ABS brackets for internal fixtures
Assembly: Locknuts + standoffs + replaceable plates
Cooling: Laser-cut side vents allow passive airflow over ESCs and motor surfaces

Electronics Layout & Internal Packaging

All electronics are mounted securely inside the armor frame, which acts as both the bot’s external skin and its packaging system — much like an insect’s exoskeleton.

Here’s how everything is arranged inside:

Component	Placement	Protection
ESP32	Center rear, on 3D-printed vibration-damping mount	Foam-lined housing
ESCs (x3)	Side walls, one per motor	Shielded with internal polycarbonate panel
Weapon Motor	Front-mounted below weapon bracket	Partial enclosure + laser-cut air vents
Drive Motors	Left & right sides, bolted to aluminum base frame	Steel motor brackets + foam strips for shock
LiPo Battery	Central, low for weight balance	Fireproof pouch + Velcro + 3D-printed enclosure
Kill Switch	Rear, accessible from outside	Flush-mounted into cutout on back armor
Wiring	Routed in channels using zip ties and cable sleeves	Heat-shrink tubing + labels for easy identification

This turns the bot into a self-contained, protected product — just like an armored laptop or a rugged phone, but with saw blades and drive motors.

Form, Shape & Material Details

Element	Description
Form	Wedge with angled front to slide under enemies
Armor	Laser-cut polycarbonate panels
Chassis	Aluminum CNC frame + 3D printed component mounts
Cooling	Passive air vents laser cut for internal heat dissipation
Color Scheme	Matte black with red LED highlights
Fastening	Locknuts, zip ties, standoffs for modular assembly

Timeline (June 1–10)

Date	Task
June 1	Final concept sketches + select weapon and bot style
June 2	Complete Fusion 360 CAD model
June 3	Laser cut armor + 3D print brackets + CNC base frame
June 4	Assemble drive system + install motors
June 5	Build and mount weapon mechanism
June 6	ESP32 + Blynk app setup and testing
June 7	Full electronics wiring and debugging
June 8	Attach armor, foam padding, and wire organization
June 9	Final system testing (drive, strike, remote, kill switch)
June 10	Documentation photos, demo video, and webpage updates

Drive & Weapon Integration

Drive System: Motors: 2 × OG555 High Torque DC Motors

Control: Skid steering — one motor per side

Wheels: Grippy rubberized wheels for traction

Power: ESCs receive PWM signal from ESP32 based on Blynk joystick input

Weapon System: Design: Circular blade inspired by mantis shrimp punch

Motor: High-speed brushed motor + dedicated ESC

Mounting: Motor fixed to internal base frame, blade exposed from wedge front

Activation: Controlled via app button (can be upgraded with sensor-triggered strike later)

Everything connects to a 3S 11.1V LiPo battery, which is monitored for voltage levels, with an optional voltage buzzer for safety.

Control System – Remote in Your Hands

Microcontroller: ESP32

App Interface: Blynk IoT mobile app

Input: On-screen joystick for movement, button for weapon activation

Communication: Wi-Fi (stronger range than Bluetooth, smoother control)

Failsafe: Kill switch cuts off battery supply if things go wrong

This system allows smooth control during matches — forward, reverse, turning, and striking — all from a mobile phone.

Final Product Thinking

Most battle bots look unfinished — like exposed wires and duct tape holding everything together.

That’s not the goal here.

My bot is designed to look and feel like a finished product, ready for the arena:

Clean cable management
Modular panels that can be removed with 4 screws
Color scheme: Matte black body, red LEDs inside the vents
No exposed electronics
Custom bracketry instead of zip-tied chaos
Vibration-tested internals to avoid failure during impacts
his makes it not only a project for FabLab but also a prototype I’d be proud to take to national-level competitions.