Design, Construction, & Calibration - Fall of 2025, Spring of 2026
Project Overview
The Fall 2025 to Spring 2026 FIRST Robotics season tasked two-team alliances with navigating a 12x12-foot arena to intake, sort, and launch 5-inch plastic artifacts (24 purple and 12 green) into elevated goals. The scoring system heavily incentivized strategic scoring, awarding bonus points for launching artifacts in prescribed color sequences, such as (Purple, Purple, Green), (Purple, Green, Purple) or (Green, Purple, Purple). Matches concluded with a race to the Base Zone, an 18x18-inch square, where teams scored final points based on partial or full parking inside the boundary.
Challenges We Faced
Strict Volume Constraints: Operating within a rigid 18-inch limit (length, width, and height) made storing and sorting three 5-inch artifacts incredibly difficult.
Software Development: With zero prior coding experience on the team, programming the drivetrain and the crucial autonomous period required steep, rapid learning.
Dynamic Sorting Requirements: We needed a highly reliable, on-the-fly sorting mechanism capable of adapting to different sequence prescriptions.
Intake Containment: Our initial intake design consumed nearly all 18 inches of vertical space, leaving no room for a protective housing, which resulted in artifacts frequently bouncing out of the robot.
Initial Design
Early Design Process
Our early prototype suffered from significant consistency issues. We utilized a ground-level intake featuring rotating elastic bands designed to propel artifacts to the top of the robot and drop them into a gravity-fed slide. Because the intake mechanism consumed 17 inches of our height limit, we could not install a roof. As a result, artifacts regularly bounced out of the feed. Furthermore, the gravity feed was inherently flawed; artifacts constantly jammed against the release servo if multiple tried to pass at once. The robot also lacked automation and suffered from a structural bias that caused the launcher to aim slightly to the left.
Improvements & Final Design
Through targeted iteration, we completely overhauled the robot's architecture to prioritize positive control over the artifacts:
Spindle Intake: We replaced the elastic web with dual-sided spindles that efficiently rotated and drove the artifacts into the revolver.
The Revolver Mechanism: We abandoned the gravity feed in favor of a motorized "revolver." This system actively spun the artifacts into specific positions, entirely eliminating jams, preventing bounce-outs, and allowing us to actively select which color to queue next.
Active Feeding: We upgraded the servo to physically push the queued artifact into the launcher. Transitioning from a passive, gravity-dependent feed to an active, motorized push drastically increased our firing reliability and rate.
My Roles
Operating in a small team of four required me to wear many hats throughout the season:
Mechanical Design & CAD: I took part in design sessions for our intake, sorting, and launching mechanism. This phase allowed me to develop core engineering skills, including 3D sketching and CAD modeling.
Manufacturing & Assembly: I translated our digital models into physical parts, utilizing precision machinery like laser cutters, and executed the final mechanical assembly.
Testing & Calibration: I helped with the mechanical calibration of the launching device, establishing two highly reliable, distinct shot distances (medium & far) for the driver to utilize during matches.
Match Strategy: During active competition, I served as the drive coach, telling the driver which color to shoot and directing the driver's next moves.
My Takeaways
This robotics season was an incredibly eye-opening introduction to the engineering design process. Driven by a highly competitive environment, I learned how to build with a definitive purpose by iterating relentlessly to out-engineer our competitors. Technically, I developed strong capabilities in CAD—specifically learning how to model spatial constraints for objects that weren't being printed to ensure proper clearances. Beyond software, it provided hands-on experience in complex mechanical assembly, electrical wiring, and the value of rapid innovation when a prototype fails.