WELDING TECHNIQUES IN FTC ROBOTICS

OVERVIEW OF WELDING IN ROBOTICS

Welding is a permanent joining method between metal parts, forming a sturdy structural skeleton for FTC robots. It provides a lightweight, high-rigidity joint and is typically reserved for the drivetrain chassis and primary robot structures due to its permanent nature.

• Welding Locations in an FTC Robot:
  • Main chassis frame
  • Gearboxes and motor mounts
  • Load-bearing cross braces
  • Shooter and intake frames when high rigidity is required

ADVANTAGES AND CHALLENGES OF WELDING

POPULAR WELDING METHODS FOR FTC ALUMINUM

Comparison of Two Aluminum Welding Methods for Robotics

• CRITICAL TECHNICAL NOTE:Direct Current (DC) welding machines CANNOT weld aluminum! Aluminum requires an Alternating Current (AC) welding machine to break through the tough surface layer of aluminum oxide (Al2O3\text{Al}_2\text{O}_3Al2​O3​). This oxide layer has a melting point of 2,072°C, much higher than pure aluminum (660°C).
• PRACTICAL EXPERIENCE FROM TOP FTC TEAMS:
  • Find professional partners: 85% of FTC teams with welded frames rely on sponsors or local machine shops. Don't hesitate to contact manufacturing companies—many are willing to support robotics teams.
  • Jigs are mandatory: When designing assemblies for welding, build jigs to hold parts in precise alignment. A good jig cuts welding time by 70% and ensures ±0.5mm\pm 0.5\text{mm}±0.5mm accuracy.
  • Heat control: For 1.5mm aluminum, weld in short 1–2cm segments and let cool for 5–10 seconds. Use an infrared thermometer to ensure surface temperature doesn't exceed 150°C.
  • Pit-stop repair kit: Prepare an emergency repair kit containing 1mm aluminum sheet, metal shears, pop rivets, a handheld drill, and metal epoxy to temporarily reinforce cracked welds.

FTC ROBOT FRAME WELDING PROCESS

7 Steps to Construct a Professional Welded Robot Frame

• STATISTICS FROM TOP FTC TEAMS:
  • Average Cost: $200–500 for a complete aluminum welded frame (materials + services)
  • Time Commitment: 15–30 hours from CAD design to finished robot
  • Weight Savings: 20–40% compared to a bolted frame of equivalent rigidity
  • Team Self-Welding Ratio: 15% (with mentors), 85% outsource to professional services
  • Popular Materials: Aluminum 6061-T6 (75%), Aluminum 7075 (20%), 4130 Steel (5%)
  • Popular Method: TIG welding (90%), MIG welding (8%), Other (2%)