Open-source social robots offer accessibility, repairability, and student empowerment, yet the build itself often presents a barrier. Existing platforms either ship pre-assembled, foreclosing hands-on learning, or expose students to unfamiliar fasteners, opaque wiring, and inaccessible service points that erode engagement. Whether targeted mechanical redesign can lower this barrier whilst maintaining structural integrity remains untested. Here we show that Design for Assembly (DfA) and Design for Disassembly (DfD) interventions reshape how a build feels before they shorten how long it takes. Working with university students in Guyana and Estonia, we applied the Double Diamond framework to co-create the Robot Study Companion (RSC) v4.1: mapping pain points, then redesigning its chassis around twist-lock fasteners, snap-fit joints, and tool-free service latches. Across two studies with developers and first-time builders, system usability climbed from Poor to Excellent (SUS 59.4 to 89.4), perceived workload trended downward (NASA-TLX 4.29 to 4.00), and mean assembly time trended downward (21.4 to 13.7 minutes, with juniors' learning effect), whilst orientation cues and navigation continuity for first-time builders emerged as the next documentation frontier. Perceived workload, not completion time, appears to govern whether students take up open hardware.
Lower cost open source robots and reinforcement learning (RL) simulation tools create new opportunities for precollege students to engage with contemporary robotics. However, translating a complete research workflow, spanning mechanical assembly, electrical setup, simulation, policy learning, system identification, and physical deployment, into a coherent course for novice learners remains challenging. We present an integrated robotics course framework that organizes these activities around a shared robotic artifact. The framework combines parallel disciplinary tracks, sequencing based on technical dependencies, progressive integration of simulation and hardware, layered performance checkpoints, and structures for balancing collaborative work with individual accountability. We illustrate the framework through a high school curriculum organized around a robot project in which pairs of students assemble an open source humanoid robot, train a walking policy in simulation, and deploy it on the physical platform. The framework was developed through an iterative design process that included formative review by five experts in robotics research, engineering, secondary STEM education, and curriculum design. Expert feedback highlighted three central design tensions: authenticity versus cognitive load, system integration versus timely visible progress, and team construction versus individual accountability. These tensions informed the final framework presented in this paper. This work offers a structured approach for adapting robotics research workflows into interdisciplinary precollege courses; future classroom studies are needed to examine implementation and student learning.
To accelerate automated remanufacturing, robotic disassembly must be considered during the product design phase. However, designers currently lack quantitative feedback to identify which structural elements hinder robotic operations. To address this, this study proposes an analytical framework that provides actionable redesign guidance focused on fastener reduction, as fasteners are numerous and ubiquitous components found in almost all manufactured products. Using a Computer-Aided Design (CAD) model and its automatically generated Contact-Connection-Constraint (CCC) graph, the framework translates robotic disassembly sequence planning outcomes into component influence scores. These scores reflect how often a component causes structural constraint violations or evaluation objective deteriorations in the robotic disassembly sequence. To visually highlight structural hindrances, the framework projects these scores onto the CAD geometry as 3D heatmaps. The system then analytically simulates the removal of highly influential fasteners. It reports the expected reductions in structural constraints, tool changes, and robot travel distances, while preventing structurally unsafe modifications by evaluating geometric stability metrics. Experiments on seven household appliances demonstrate that the framework successfully targets redundant fasteners. Removing the recommended fasteners simplified the structural dependencies by eliminating between 8 and 132 structural constraints on the graph depending on each product's structural configuration. Furthermore, it improved robotic operational efficiency by eliminating unnecessary tool change operations and shortening travel distances by 165 to 1675 millimeters wherever structurally permissible.
We provide a novel end-to-end framework for the execution of an assembly operation by two robotic arms, given the digital CAD models of the parts and their desired relative placement in their assembled state. We analyze and demonstrate the advantages of using two robotic arms simultaneously in tight assembly operations, compared to single-arm systems. Our method is implemented in both simulation and using physical robots. It provides theoretical guarantees on execution time and trajectory accuracy, supported by empirical evidence. In particular, we show that coordinated movement of two arms reduces average execution time by more than 50% compared to using a single arm only, produces higher-quality trajectories, and accelerates the search for valid robot placements. Furthermore, we establish bounds on the required dimensions of the robotic cell. Our open source software together with real-life video demonstrations are available in our project page.