NextGen Tinker

Abstract

This project presents the design, simulation, fabrication, and assembly of a low-cost, lightweight robotic gripper using Computer-Aided Design (CAD) in FreeCAD, additive manufacturing (3D printing), and servo-driven actuation. Robotic grippers are critical end-effectors in automation systems, enabling robots to perform essential tasks such as gripping, holding, and manipulating objects. However, conventional industrial grippers are often expensive, application-specific, and complex to manufacture. To address these limitations, this work introduces a customizable and modular gripper suitable for educational, research, and lightweight industrial applications.

The gripper was modeled in FreeCAD with a modular architecture, allowing components such as the base housing, finger arms, gears, and pads to be fabricated individually for ease of replacement and customization. Simulation and analysis were performed to verify jaw motion, stress distribution, and torque requirements. 3D printing using PLA filament was employed to fabricate the components with optimized settings (FDM printing, 0.2 mm layer height, 20–30% infill). Actuation was achieved using SG90 micro servo motors, selected for their compact size, energy efficiency, and ease of control through PWM signals from Arduino/ESP32 microcontrollers.

Testing confirmed effective pick-and-place functionality for lightweight objects, demonstrating adequate gripping force, smooth operation, and modular reconfigurability. The proposed design proved to be affordable, accessible, and easy to fabricate, making it well-suited for educational robotics, automated inspection, and assistive technology. Recommendations for future scope include integrating higher torque actuators, advanced materials, tactile sensors, and AI-based vision systems for intelligent manipulation.

Keywords

Robotic Gripper, CAD Modeling, FreeCAD, 3D Printing, Servo Actuation, Pick-and-Place Automation, Modular Design, Educational Robotics