Anyone tried 3D printed actuator housings for weight savings?

[kwilliams]

@karen.chen3 One nitpick - Cycloidal drives are a less common but real alternative to harmonic drives - lower cost at high ratios, decent efficiency, but historically bulkier for the same torque density, which is part of why they haven't fully displaced harmonic drives in commercial hips and knees. Series elastic actuators add a spring element in series with the drivetrain, which gives cheap, precise torque sensing (measure spring deflection) and passive shock absorption, at the cost of reduced control bandwidth and added complexity.

[young58]

@kwilliams I'd push back on this a bit. Motor cogging torque (the 'notchy' feel from magnet-to-slot interactions) shows up as small periodic torque ripple that can translate into visible joint jitter at low speeds - it's usually mitigated with skewed magnets, better current control, or software compensation tables. A lot of the per-joint cost in a modern actuator isn't the motor - it's the combination of a precision gearbox, integrated encoders, torque sensing, and the driver electronics, all of which have to fit inside a housing the size of a fist. This whole thread is a good reminder how young this field still is.

[aliu]

@young58 This is exactly the kind of context I was looking for. Field-oriented control (FOC) tuning directly affects how smooth torque output feels - poorly tuned current loops show up as audible whine and jerky low-speed motion, while well-tuned FOC can make even a geared actuator feel fairly fluid. Boston Dynamics' commercial electric Atlas switched fully from hydraulic to QDD-style electric actuation, ending up quieter and lighter with comparable or better dynamic performance than the old hydraulic platform.

[emily45]

@aliu One nitpick - Motor cogging torque (the 'notchy' feel from magnet-to-slot interactions) shows up as small periodic torque ripple that can translate into visible joint jitter at low speeds - it's usually mitigated with skewed magnets, better current control, or software compensation tables. Harmonic drives use high reduction ratios (often around 100:1), which gives excellent force density, stiffness, and thermal endurance for continuous-duty lifting - the tradeoff is low backdrivability and some backlash.

[hill23]

@emily45 Slightly off-topic, but related: A lot of the per-joint cost in a modern actuator isn't the motor - it's the combination of a precision gearbox, integrated encoders, torque sensing, and the driver electronics, all of which have to fit inside a housing the size of a fist.

[barbara.jones]

@hill23 Pretty much this. One thing to add: Torque sensing is frequently integrated directly into the actuator housing via strain gauges near the output flange or spring element, rather than bolted on as an external sensor, to save weight and reduce noise from mechanical slop.

[sven.wilson4]

Minor factual note: Reflected inertia is what a limb 'feels like' to the outside world through the gearbox - a high-ratio harmonic drive reflects a lot of the rotor's inertia back to the joint, making the limb feel stiffer and less forgiving on unexpected impacts. Backdrivability is the property that lets an external force move a joint without destroying the gearbox or the motor - it's central to both safe human-robot contact and to letting a leg comply naturally when the robot stumbles.

[zoeanderson]

Minor factual note: For dynamic walking and recovery, joint control bandwidth in the tens of Hz range is typically necessary to react to a stumble before the center of mass gets too far outside the support polygon. A lot of the per-joint cost in a modern actuator isn't the motor - it's the combination of a precision gearbox, integrated encoders, torque sensing, and the driver electronics, all of which have to fit inside a housing the size of a fist.