Few robots are more recognisable than WALL·E; his cute appearance and distinctive personality make him instantly endearing to anyone who sees him! In this project, I designed a WALL·E replica with the aim to allow each of the robot's joints to be moveable by hand or using servo motors.

Loosely based on the dimensions and design of ChaosCoreTech's Wall-E replica (https://www.thingiverse.com/thing:1681442), this version was designed from scratch in Solidworks and allows 7 of the joints to be actuated, including the arms, neck, head and eyes. The robot design has the following features:

• Each eye can be raised and lowered independently with servo motors.
• There is room in each eye to add a small camera.
• The head can look left and right using a servo motor.
• The neck is actuated at two joints, allowing the head to look up/down and to be raised/lowered.
• Each arm has a motor at the shoulder to move it up/down.
• The arms consist of pressure-fit joints, hands, and fingers, which can be manually posed.
• The tank treads (skid steering) are fully 3D printed and can be powered using two 12V DC geared motors.

This is an ambitious project, aimed at people who want to build a fully animatronic WALL·E robot with servo-controlled joints. It took me about 3 months to design and assemble the robot, with more than a month spent on just 3D printing all of the parts. In total, there are 310 parts (although 210 of those are very small and make up the tank treads). A PDF containing a list of all the parts and the quantity of each that needs to be printed is included in the download section with the STL files.

If you feel up for the challenge of tackling this project and printing all the files, please let me know how it goes! Please note that all STL files are in millimetres. The design is scaled at approximately 41% of the size of the robot in the movie.

A detailed description of the robot assembly and coding instructions can be found on my website:
https://wired.chillibasket.com/3d-printed-wall-e/

The code used to program the robot and Raspberry Pi can be found on GitHub. If you have any programming-related issues or questions, please ask them on my website.
https://github.com/chillibasket/walle-replica

Here is a video of my WALL·E robot in action:
https://www.youtube.com/watch?v=QidMAtTzF88