Customer Case | Rapid Prototyping of Components for an Embodied Robot
Industry: Robotics
Materials: Aluminum 6061-T6, Carbon Fiber Reinforced Nylon (PA12-CF)
Post-Processing: Anodizing, Bead Blasting
Manufacturing Processes: CNC Machining, Industrial SLS 3D Printing
Outcome: Rapid delivery of key functional components for joint housings and servo brackets
Robots Aren’t Just Assembled—They’re Refined Through Trial and Error
For German startup Mech Robotics, building a fully functional humanoid robot prototype isn’t just about CAD designs and mechanical assembly. It’s a continuous loop of prototyping, iteration, structural optimization, and tight collaboration between design and manufacturing teams.
The company’s latest prototype, M-01, is designed for assistive and collaborative scenarios in healthcare and industrial environments. It features 17 degrees of freedom, modular drive units, and a multi-sensor fusion platform. Ahead of a major robotics technology exhibition in April, the team urgently needed to prototype joint reducer housings and servo module brackets for final validation and assembly testing.
The Challenge: From “Beautiful Design” to “Manufacturable Reality”
In the initial design, several mounting holes required ultra-tight tolerances of ±0.01 mm, along with complex chamfers and slot features—all intended to ensure precise assembly. However, these perfectionist specifications introduced serious manufacturing challenges, leading to skyrocketing costs (40% over budget) and unacceptable delays in lead time.
Some components were originally designed in aluminum 7075 due to its high strength. However, this material is difficult to machine, not ideal for anodizing, and poorly suited for repeated disassembly—particularly for a tradeshow prototype. In short, the design was overengineered, adding cost and complexity without clear functional benefit.
The Solution: From Supplier to Engineering Collaborator
Referred by peers in the industry, Mech Robotics approached us—Leanplans—for support. As a manufacturing partner experienced with humanoid robotics, we understood that the client didn’t just need parts; they needed a design-aware manufacturing solution.
Our Leanplans Multi-Agent System delivered the first DFM report within 1 hour. A full DFM review followed within 24 hours, along with a remote design meeting between our engineers and Mech’s structural team. We proposed three key optimizations:
- Structural simplification: Replacing sharp, non-functional corners with standard R2 radii to reduce toolpath complexity and tool changes
- Tolerance relaxation: Maintaining ±0.02 mm only on key mating surfaces, loosening others to ±0.05 mm, supported by dowel pin positioning
- Material substitution: Switching from all-aluminum brackets to SLS-printed carbon fiber PA12, reducing weight by 30% and lead time significantly
The Result: Faster Than Just Fast—Responsive and Aligned
Once the plan was finalized, we machined the joint housings using 5-axis CNC from aluminum 6061-T6, chosen for its balanced strength, machinability, and anodizing performance.
For the servo brackets, we used industrial-grade SLS 3D printing with carbon fiber reinforced PA12, offering high strength-to-weight ratio and excellent dimensional stability—ideal for lightweight hollow structures.
All parts were manufactured within 5 working days and delivered within 14 calendar days. CMM inspection confirmed that all key dimensions were within ±0.02 mm. At the exhibition, the robot was assembled smoothly and completed live demonstrations, drawing attention from investors and media.
“We were stuck in a mindset of building strictly to drawings,” the structural lead at Mech Robotics later shared. “Leanplans helped us realize what it means to design for manufacturing—it accelerated everything.”
Beyond Prototypes—A Partner That Builds With You
Though this project was a single-event prototype, it proved how critical it is for robotics startups to work with partners who understand both design intent and manufacturing reality.
At Leanplans, we’re supporting a wide range of robotics teams—humanoids, quadrupeds, and special-purpose robots—with everything from drive unit frames and end effectors to perception module housings. Our services span DFM consultation, material selection, process matching, and multi-process rapid prototyping.
If you’re facing the gap between what you can imagine and what you can build, send us your drawing. Sometimes one round of feedback is all it takes to find a faster, smarter path forward.
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