{"id":186699,"date":"2022-02-18T09:28:47","date_gmt":"2022-02-18T09:28:47","guid":{"rendered":"https:\/\/facfox.com\/news\/?p=186699"},"modified":"2022-01-18T09:29:34","modified_gmt":"2022-01-18T09:29:34","slug":"battlebots-new-ghost-raptor-has-some-3d-printed-bite","status":"publish","type":"post","link":"https:\/\/facfox.com\/news\/battlebots-new-ghost-raptor-has-some-3d-printed-bite\/","title":{"rendered":"BattleBots\u2019 New Ghost Raptor Has Some (3D Printed) Bite"},"content":{"rendered":"

A robotic, dinosaur ghost, that shoots fire out of her 3D print<\/a>ed jaw. That\u2019s Ghost Raptor for the 2022 season of BattleBots but it could be pretty much any maker\u2019s dream bot. Team Raptor (Chuck Pitzer, Eric Diehr, Sabri Sansoy) teamed up with Designer Anouk Wipprecht and Xo Wang for the 2021 BattleBots competition. Team Raptor has been part<\/a>icipating in robotic fighting tournaments since 1999 and this year, to add even more style and badassery to the terrordactyl (cit.) bot, the team worked with Wipprecht and metal DED 3D print<\/a>ing<\/a> company Formalloy to create a metal 3D print<\/a>ed jaw that opens to spit fire at its enemies. Thanks to Anouk\u2019s part<\/a>icipation in this season, we had the opportunity to sit down with her and Team Raptor\u2019s Team Captain Chuck Pitzer to learn more about if and how 3D print<\/a>ing<\/a> is making a difference.<\/p>\n

For the few who may not be familiar with the show, BattleBots began airing in the US in 2000, and after a few seasons, it was revived in 2015. The sixth season of the second run i<\/b>s currently airing on Discovery and streaming on Discovery+ in the US (and Netflix in many countries around the world). In the show, 250-pound robots do their best to destroy or disable each other using whatever means available, during matches that are three minutes long.<\/p>\n

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Photo by Daniel Longmire.<\/figcaption><\/figure>\n<\/div>\n<\/div>\n

Enter the Ghost<\/h2>\n

Drawing epithets such as \u201cghost of winning future\u201d, \u201cterrordactyle\u201d and \u201carma-get-it-on\u201d from the show\u2019s ring announcer Faruq Tauheed, Team Raptor\u2019s new Ghost Raptor is a heavyweight robot that competed in the latest seasons of BattleBots, and this year it will start<\/a> fighting in episode 6, on January 27th. Team Raptor is a veteran team: every year its robot is improved to become more devastating but making changes can be a very challenging and expensive process.<\/p>\n

\u201cWe try to reuse as much as possible, but that is a very limiting design constraint,\u201d Pitzer told 3dpbm. \u201cMuch of those decisions are based on what the most expensive components in the robot are \u2013 either off-the-shelf or custom fabricated. Normally re-engineering something as simple as a weapon shaft diameter will ripple through the entire design and lead to a lot of extra expense.\u00a0 Changing the drive system, for example, can lead to a massive re-design. The chassis that is on Ghost Raptor is the same chassis that was developed for a prior robot called Preda Raptor. Many of those titanium chassis pieces have existed for over 12 years and have been re-used for multiple competitions and TV shows.\u201d<\/p>\n

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Team Raptor (Chuck Pitzer, Eric Diehr, Sabri Sansoy) teamed up with Designer Anouk Wipprecht and Xo Wang for the 2021 BattleBots competition. Photo by Daniel Longmire.<\/figcaption><\/figure>\n<\/div>\n<\/div>\n

With such tight design constraints, cost limitations and uniqueness of the part<\/a>s, 3D print<\/a>ing<\/a> makes a lot of sense. However, until recently, it was only used for prototyping. With the increasing accessibility of metal AM technologies, some teams have start<\/a>ed to look at metal 3D print<\/a>ing<\/a> for actual BattleBot part<\/a>s. That\u2019s something that Anouk is good at, as an expert in innovative out-of-the-box solutions using a variety of 3D print<\/a>ing<\/a> technologies.<\/p>\n

\u201cMy friend Sabri Sansoy (Machine Learning specialist) hit me up if I wanted to join the team, and I said immediately yes! Since \u2013 of course \u2013 I love robots. There was not much time as it was a few weeks before the show so me and Chuck [Pitzer] mainly worked online on some of the improvements. I worked with Sabri on some of the aesthetic and design elements. The idea was to come all together in Las Vegas ahead of time, and merge everything together to get ready for the battles. It has been an awesome adventure.\u201d<\/p>\n

Pedal to the metal<\/h2>\n

Working with Anouk, Team Raptor decided to 3D print<\/a> the jaws-shaped front grill of the Ghost Raptor\u2019s new flamethrower weapon. \u201cWe never really used 3D print<\/a>ing<\/a> for most things because the perception was that they were not rugged enough,\u201d Pitzer explained. \u201cWe did normally use it for internally mounting electronic part<\/a>s and spacing batteries apart<\/a>, etc..\u201d Exterior part<\/a>s that have to withstand the brute force of enemy weapons, however, are a different matter. In addition, while metal 3D print<\/a>ing<\/a> has proven to produce part<\/a>s strong enough for rockets engines and turbine part<\/a>s, it has not often been used on part<\/a>s that need to take a serious beating.<\/p>\n

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\u201cWe could machine it out but we wanted to go a bit more in detail possibly in regards to design, so Melanie [Lang] of FormAlloy proposed we use their Directed Energy Deposition (DED) metal 3D print<\/a>ing<\/a> technology,\u201d Anouk told 3dpbm.<\/p>\n

\u201cThe frontal grill is a unique component with a fairly complex geometry that would be challenging and time-consuming to machine,\u201d Melanie confirmed. \u201cFormAlloy was able to build the part<\/a> in just a few hours from the CAD file.\u201d High-strength aluminum 6061 RAM was selected as the ideal material to use as it would be able to withstand the heat and aggressive conditions these robots are subjected to, but also lightweight enough to keep the robot within the requirements.<\/p>\n

\u201cWe made several iterations and also replacement part<\/a>s so we could test them out. They screwed right in so they were easy to exchange ahead of a battle.\u201d The ability to go directly from CAD (the team used design software from team sponsors Onshape to part<\/a> also made 3D print<\/a>ing<\/a> an ideal solution in terms of time reduction.<\/p>\n

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Manufacturing on Demand<\/h4>\n
Order custom parts through our online manufacturing network. Low cost, fast delivery. Upload your design for free quotes now!<\/div>\n<\/div>\n

<\/i> Get Quote<\/a><\/p>\n<\/div>\n

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Formalloy\u2019s X-series metal DED 3D printer.<\/figcaption><\/figure>\n

Formalloy is a California-based manufacturer of metal DED 3D print<\/a>ers. FormAlloy\u2019s X & L-Series Directed Energy Deposition (DED) systems feature closed-loop control, variable-wavelength lasers, and FormAlloy PF and ADF powder feeders for gradient or bi-metallic structures. \u201cFormAlloy\u2019s DED technology is ideal for this type of project because components are built or repaired quickly and efficiently in a single step, and often require minimal post-processing,\u201d Melanie explained. \u201cIt is an efficient process and capable of building with multiple materials, including various aluminum alloys. If a limitation exists with materials, timeline, or performance, 3D print<\/a>ing<\/a> may be a great solution,\u201d Melanie added.<\/p>\n

I knew Melanie through my network \u2013 Anouk said \u2013 and she is motivated by developing disruptive technologies that challenge the status quo [\u2026] we are both looking to create geometrically complex components out of exotic materials to push the boundaries. But pricing and lead times are always important to consider. FormAlloy was the only company that was open to working with us on such a short timeline, and on such an experimental project. None of the other companies that I approached were flexible enough to turn around these part<\/a>s in time. Melanie even joined us in Las Vegas during the first show!\u201d<\/p>\n

Does it burn?<\/h2>\n

The flamethrower elements are mounted behind the \u2018grill\u2019, with the nozzle and igniter in the middle. This is what allowed GhostRaptor to spit fire out of its \u201cmouth\u201d, while the 3D print<\/a>ed part<\/a>s held everything together. With such high temperatures, the DED part<\/a>s held it very well, whereas plastic 3D print<\/a>ed test pieces start<\/a>ed to burn almost immediately after firing up the flamethrower.<\/p>\n

The flamethrower components needed to be able to resist exposure to the butane-fueled flame for short periods. The mounts for these were machined \u2013 but the more aesthetic and complicated part<\/a>s (such as the teeth) were all 3D print<\/a>ed using FormAlloy\u2019s expertise.<\/p>\n

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The first test part<\/a>s in standard 3D print<\/a>ed PLA got smashed right away into a wall with full power in the test box. A \u2018test box\u2019 is a special enclosed, small armored area used for testing the operation of a single robot that you use after your configuration to test your robot out. \u201cWe fired the GhostRaptor. Chuck slammed it (on purpose to test the rigidity of the bot) against the four walls and a piece flew off almost immediately. For the real battle therefore we switched to the metal 3D print<\/a>ed part<\/a>s and that \u2013 even after the real battle \u2013 had just minimum damage, to what I can remember. I saw the piece afterward and only the top teeth were shaved off a bit,\u201d Anouk said.<\/p>\n

The ghost of 3D print<\/a>ed futures<\/h2>\n

This first experience convinced Anouk that 3D print<\/a>ing<\/a> can play a major part<\/a> in the future of Battlebots. \u201cI think it definitely has potential,\u201d she tells us, \u201cbut \u2013 as any part<\/a> on your bot \u2013 what is weak, gets mauled pretty rigorously. In our case, we had two long forks next to the \u2018grill\u2019 or \u2018mouthpiece\u2019 either way so it was an easy choice to mount the flamethrower nozzle there so it had some protection from each fork.<\/p>\n

\u201cI think \u2013 Chuck Pitzer added \u2013 the trend in BattleBots will be to see a lot more metallic 3D print<\/a>ed part<\/a>s.\u00a0 A number of teams have already secured sponsorships and are pioneering the use of 3D print<\/a>ed materials in the sport.\u201d<\/p>\n

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In the near future, 3D print<\/a>ing<\/a> companies may find BattleBots as an ideal arena to promote and present their technologies. \u201cTeams should engage with sponsors ahead of time!\u201d Anouk concluded. \u201cGhostRaptor is a veteran \u2013 Chuck created his first robot 20+ years ago \u2013 so it\u2019s a pretty well-known robot. We were super happy with the support from Onshape, guardDog.ai, FormAlloy and others so we could leverage design with software and technologies while making enough material and hardware purchases for GhostRaptor. But it would be really hard to create these projects without a budget to start<\/a> with. Bots can cost between $5,000 and $50,000 USD to build and are mostly constructed by regular people doing this as an incredibly expensive hobby.<\/p>\n

Even beyond robot-makers and 3D print<\/a>ing<\/a> companies, all companies interested in sponsoring a robot can reach out to rookie teams or a team that is new in the game. 3D print<\/a>ing<\/a> can be beneficial in many part<\/a>s of the BattleBot creative workflow, from polymer prototypes and tools to ultra-hard metal part<\/a>s. \u201cOften younger teams don\u2019t even know how to go about sponsorships. But have all the skills to make for a really good fight,\u201d Anouk concluded. And we\u2019d love to see exactly how much a more advanced and creative design can help a robot break more stuff faster.<\/p>\n

On location BattleBots photos by Daniel Longmire<\/em><\/p>\n

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* This article is reprinted from 3D Printing Media Network<\/a>. If you are involved in infringement, please contact us to delete it.<\/p>\n

<\/i> Author:\u00a0Davide Sher<\/p>\n","protected":false},"excerpt":{"rendered":"

A robotic, dinosaur ghost, that shoots fire out of her 3D printed jaw. That\u2019s Ghost Raptor for the 2022 season of BattleBots but it could be pretty much any maker\u2019s dream bot. Team Raptor (Chuck Pitzer, Eric Diehr, Sabri Sansoy) teamed up with Designer Anouk Wipprecht and Xo Wang for the 2021 BattleBots competition. Team Raptor has been participating in robotic fighting tournaments since 1999 and this year, to add even more style and badassery to the terrordactyl (cit.) bot, the team worked with Wipprecht and metal DED 3D printing company Formalloy to create a metal 3D printed jaw that opens to spit fire at its enemies. 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That\u2019s Ghost Raptor for the 2022 season of BattleBots but it could be pretty much any maker\u2019s dream bot.","robots":{"index":"index","follow":"follow","max-snippet":"max-snippet:-1","max-image-preview":"max-image-preview:large","max-video-preview":"max-video-preview:-1"},"canonical":"https:\/\/facfox.com\/news\/battlebots-new-ghost-raptor-has-some-3d-printed-bite\/","og_locale":"en_US","og_type":"article","og_title":"BattleBots\u2019 New Ghost Raptor Has Some (3D Printed) Bite","og_description":"A robotic, dinosaur ghost, that shoots fire out of her 3D printed jaw. That\u2019s Ghost Raptor for the 2022 season of BattleBots but it could be pretty much any maker\u2019s dream bot. Team Raptor (Chuck Pitzer, Eric Diehr, Sabri Sansoy) teamed up with Designer Anouk Wipprecht and Xo Wang for the 2021 BattleBots competition. Team Raptor has been participating in robotic fighting tournaments since 1999 and this year, to add even more style and badassery to the terrordactyl (cit.) bot, the team worked with Wipprecht and metal DED 3D printing company Formalloy to create a metal 3D printed jaw that opens to spit fire at its enemies. Thanks to Anouk\u2019s participation in this season, we had the opportunity to sit down with her and Team Raptor\u2019s Team Captain Chuck Pitzer to learn more about if and how 3D printing is making a difference. A robotic, dinosaur ghost, that shoots fire out of her 3D printed jaw. 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