Printing

Every structural part is a plate, a cup or an adapter that prints flat on a 250 mm bed without supports on a load-bearing face. Three materials, three settings profiles, one printer.

At a glance

Print settings

Profile	Parts	Nozzle	Layer	Walls	Infill	Temps	Other
Structural PETG-CF	Adapters, brackets, cups, plates, thigh blocks, foot plates, pelvis, torso plates, neck	0.4 mm hardened steel	0.2 mm	6 (2.4 mm)	35 % gyroid	255–270 °C / 80 °C bed	Enclosure recommended; dry the spool; 100 % infill on the hip-roll bracket, hip-yaw housing, thigh block and ankle bracket
Covers PLA	Side, front and back panels, head shell, electronics tray, battery cradles, gripper body and fingers	0.4 mm	0.2 mm	3	15 % gyroid	215 °C / 60 °C	Any PLA. PLA+ or PETG if the robot lives somewhere warm
Soft TPU 95A	Soles, finger pads	0.4 mm	0.2 mm	3	100 %	225 °C / 40 °C	25–30 mm/s, retraction off or 1 mm, direct drive

Orientation rules

Plates (shank, forearm, torso, foot) print flat on their largest face. Layer lines then run in the plane of the load, not across it.
Cups and adapters print with the bore vertical. The output-adapter discs print flange-face down so the bolted face is the smooth first layer.
Brackets with cups (hip-roll, hip-yaw, thigh, ankle, shoulder, yoke, upper arm) print on their plate face with the cup standing up; the mount rings are horizontal there and print without supports, the collars need supports only where they bridge to the plate. The print column gives the orientation per part.
Right-side parts marked mirror are the left STL mirrored in the slicer, not a separate file.

After printing

Bearing pockets are cut 0.2 mm over the bearing diameter, actuator bores 0.5 mm over the housing, coupler hubs 0.1 mm under the bearing bore. Printed holes shrink; ream or sand to fit: a bearing should press in by hand with a light tap, an actuator should slide in with no play.
Heat-set inserts: M3 in the wrist adapters and covers, M5 in the torso plates. The joint kits use through screws into the actuators, no inserts. Set inserts with a soldering iron at 230 °C, square, flush.
Clearance holes for M4 print at 4.4 mm; drill to 4.5 mm if the screw does not pass freely.
Weigh the first of each structural part and compare with the estimate in the table. A part 30 % heavier than the estimate has the wrong infill; 30 % lighter has under-extruded walls.

Printed parts

Masses are the STL volume × density × fill factor (see the mass budget); envelope is the STL bounding box. Click an ID to see the part on the robot, the file link to download it. SHA-256 prefixes are in the manifest, print_files.json.

ID	Part	Material	Qty	g each	Envelope (mm)	Print	File

Filament plan

Material	On the robot	Buy	Print time (rough)

Print time assumes 20 g/h for PETG-CF at these settings, 25 g/h for PLA and 10 g/h for TPU on one printer. Two printers halve it.