🛡️ 7 Ultimate Combat Robot Chassis Materials for 2026

What if the secret to an unbeatable robot isn’t a bigger weapon, but the very bones it’s built from? At Robot Fighting™, we’ve seen legendary bots crumble into scrap metal not because their weapons failed, but because their chassis couldn’t handle the shock. Choosing the right combat robot chassis materials is the difference between a champion that dominates the arena and a pile of bent aluminum that barely makes it to the first round. From the brute force of AR50 steel to the lightweight agility of 7075-T6 aluminum and the shock-absorbing magic of UHMW, every material tells a story of strength, weight, and survival.

In this deep dive, we’re not just listing specs; we’re sharing war stories from the trenches of the Robot Fighting League. We’ll reveal why a bot made entirely of titanium might be overkill for a pusher but essential for a spinner, and how 3D printed Onyx is quietly revolutionizing the antweight class. We’ll even break down the specific failure modes that took down some of the most famous bots in history, so you can avoid their fate. Whether you’re a seasoned engineer or a curious newcomer, understanding these materials is your first step toward building a machine that doesn’t just fight, but wins.

Key Takeaways

• Material Selection is Critical: The right chassis material balances strength-to-weight ratio, impact resistance, and workability to match your bot’s specific weapon and strategy.
• No “One-Size-Fits-All”: Steel offers unmatched toughness for heavyweights, aluminum provides the best balance for agility, and polymers like UHMW excel at energy absorption in lighter classes.
• Construction Matters: How you join materials—whether through TIG welding, bolting, or billet machining—is just as important as the material itself for preventing catastrophic failure.
• Design for Failure: Understanding how materials deform (elastic vs. plastic) helps you design chassis that absorb energy rather than shatter under the force of a 20 mph weapon strike.

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Table of Contents

• ⚡️ Quick Tips and Facts
• 📜 From Scrap Yards to Battle Arenas: A Brief History of Combat Robot Chassis Materials
• 🏗️ The Big Three: Aluminum, Steel, and Titanium Showdown
• 🔩 Machined vs. Fabricated: Choosing Between Bilet, Welded, and Bolted Chassis Designs
• 🛡️ Advanced Composites and Polymers: When Carbon Fiber and UHMW Outperform Metal
• ⚖️ Weight Distribution and Center of Gravity: How Material Choice Affects Maneuverability
• 🔨 Machining Challenges: Why 7075-T6 Aluminum is a Machinist’s Best Friend (and Foe)
• 🔧 Joing Techniques: TIG Welding, Riveting, and Epoxy Bonding for Maximum Durability
• 💥 Impact Resistance and Energy Absorption: Which Material Survives the Heaviest Hits?
• 🛠️ 7 Essential Steps to Selecting the Perfect Chassis Material for Your Bot
• 🧪 Real-World Case Studies: Analyzing Chassis Failures and Victories in Major Tournaments
• 🛒 Where to Buy: Top Suppliers for Aerospace-Grade Metals and Polymers
• 🏁 Conclusion
• 🔗 Recommended Links
• ❓ FAQ: Your Burning Questions About Robot Chassis Materials Answered
• 📚 Reference Links

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⚡️ Quick Tips and Facts

Welcome, fellow robot gladiators and engineering enthusiasts, to the ultimate guide on combat robot chassis materials! Here at Robot Fighting™, home of the Robot Fighting League, we’ve seen it all – bots made from everything from repurposed street signs to aerospace
-grade alloys. Choosing the right material for your bot’s bones is paramount to its survival and success in the arena. It’s not just about brute strength; it’s about balancing weight, durability, workability, and,
let’s be honest, your budget! If you’re looking to dive deeper into the world of robot combat, check out our main hub on Robot Fighting.

Here are some quick hits to get your gears turning:

• Alloy Advantage ✅: For most weight classes, 7075-T6 aluminum is a fantastic all-rounder, offering a great strength-to-
  weight ratio. It’s tough, relatively easy to machine, and widely available.
• Titanium Toughness 💪: If you’re aiming for the absolute pinnacle of durability and have the budget, titanium is king
  . It’s lighter than steel and stronger than aluminum, making it ideal for critical armor and weapon components.
• Polymer Power 🛡️: Don’t underestimate plastics! UHMW
  (Ultra-High Molecular Weight Polyethylene) is excellent for absorbing impacts and can be surprisingly resilient, especially in lighter weight classes or as sacrificial armor. Lexan (polycarbonate) is also a strong,
  shatter-resistant material, often used for clear armor or internal components, boasting 250 times the strength of glass.
• 3D Printing Potential 💡: For smaller bots (antweight, beetleweight), 3D printed chassis using advanced filaments like NylonX or Onyx (carbon fiber-infused nylon) offer incredible design freedom and impressive strength-to-weight.

Weight Class Matters ⚖️: A material perfect for a 1lb antweight might be completely inadequate for a 250lb heavyweight. Always consider your bot’s weight class first and foremost.
*
Workability Woes ❌: Some materials, like hardened steel or certain titanium alloys, are incredibly difficult to cut, drill, or weld without specialized tools. Factor this into your build plan!

• Cost vs
  . Performance 💰: While exotic materials offer performance benefits, they come at a higher cost. Sometimes, a clever design with a more common material will outperform an expensive, poorly designed bot.

📜 From Scrap Yards to Battle

Arenas: A Brief History of Combat Robot Chassis Materials

Back in the wild west days of robot combat, builders often scrounged for whatever they could get their hands on. We’re talking repurposed street signs, old car parts, and even
kitchen appliances! It was a glorious, chaotic time where ingenuity often triumphed over pristine engineering. The early pioneers of robot fighting, much like the first gladiators, used what was readily available and adapted it for battle.

As the sport evolved and
moved from informal garage brawls to organized leagues and televised events, the demand for more predictable, durable, and performance-oriented materials grew. Builders quickly learned that a flimsy frame meant a quick exit from the arena. The focus shifted from ”
what can I find?” to “what can I engineer?”

Initially, mild steel and basic aluminum alloys were the workhorses. Steel offered brute strength and weldability, though at a significant weight penalty. Aluminum, while
lighter, was often seen as too soft for direct impacts. However, as builders experimented with different alloys and construction techniques, the potential of these materials began to shine. The development of stronger aluminum alloys and more sophisticated fabrication methods revolutionized chassis design.

Then
came the plastics. Materials like UHMW (Ultra-High Molecular Weight Polyethylene) and Lexan (polycarbonate) entered the scene, offering incredible impact absorption and ease of fabrication, especially for lighter bots where every gram counts. We remember one builder, years ago, who built an entire antweight out of a cutting board – and it surprisingly held its own for a few rounds! It was a testament to the fact that sometimes
, the simplest solutions are the most effective.

Today, the landscape is far more diverse, with builders leveraging everything from advanced composites like carbon fiber to specialized 3D printing filaments. This evolution in materials has directly contributed to the incredible
complexity, power, and resilience we see in modern combat robots. The journey from scrap yards to sophisticated battle arenas is a testament to human (and robotic) ingenuity!

🏗️ The Big Three: Aluminum, Steel, and Titanium Show

down

When it comes to the metal backbone of your combat robot, these three materials dominate the discussion. Each has its champions and its detractors, and choosing the right one is like picking your favorite weapon – it depends on your fighting style!

Aluminum: The Lightweight Contender 🥈

Aluminum is a perennial favorite for many combat robot builders, especially in weight classes where every ounce matters. It offers an excellent strength-to-weight ratio and is relatively easy to machine and
fabricate.

Pros:

• Lightweight: Significantly lighter than steel, allowing for more armor or weapon mass.
• Good Strength-to-Weight: Especially true for alloys like 7075-T

• Workable: Easier to cut, drill, and machine than steel or titanium.
• Corrosion Resistant: Naturally forms a protective oxide layer.

Cons:

• Lower Impact Resistance: Can
  dent, bend, or tear more easily than steel or titanium under heavy, focused impacts.
• Fatigue Life: Can be prone to fatigue cracking under repeated stress cycles if not designed correctly.
• Welding Challenges
  : Some high-strength alloys are difficult to weld effectively without specialized equipment and expertise.

Popular Aluminum Alloys for Combat Robots

Alloy Type	Key Characteristics	Typical Applications	Notes
:—	:—	:—	:—
6061-T6	Good strength, excellent corrosion resistance, easily weldable.	General structural components, motor mounts, less critical armor.	A great all-rounder for beginners.

| 7075-T6 | High strength, comparable to many steels, good fatigue resistance. | Primary chassis components, weapon mounts, high-stress armor. | Our team’s go-to for serious builds
. Requires more careful welding. |
| 2024-T3 | High strength, good fatigue resistance, but less corrosion resistant. | Internal structural elements, non-exposed components. | Less common for external chassis due
to corrosion. |

We’ve personally built several successful beetleweights and antweights using 7075-T6 aluminum for the frame, and it’s held up remarkably well against spinners and hammers. The key is often
in the design – distributing the load and reinforcing critical areas. For sourcing, McMaster-Carr is a fantastic resource for various aluminum sheets, bars, and extrusions.

Steel: The Un

yielding Juggernaut 🥇

When you need sheer, unadulterated toughness, steel is your huckleberry. It’s heavier than aluminum and titanium, but its impact resistance and yield strength are often
unmatched, making it a favorite for heavyweights and bots designed to take (and dish out) massive punishment.

Pros:

• High Strength and Toughness: Excellent resistance to bending, denting, and shattering.

• Good Weldability: Many common steel alloys are relatively easy to weld.

• Cost-Effective: Often more affordable than titanium or high-strength aluminum alloys.

Cons:

• Heavy: Significant
  weight penalty compared to aluminum and titanium, limiting other components.
• Corrosion: Requires coatings or treatments to prevent rust.
• Machining Difficulty: Harder to cut and drill than aluminum, requiring more robust tools.

Common Steel Types for Combat Robots

Steel Type	Key Characteristics	Typical Applications	Notes
Mild Steel (A36)	Good weld
ability, relatively soft, easy to work.	Internal bracing, less critical structural elements, practice frames.	Good for learning, but not for primary armor in serious combat.
**High-Strength Low-Alloy (HSLA) Steel
(e.g., A514)**	Higher strength than mild steel, good weldability, good toughness.	Primary chassis, weapon mounts, heavy armor.	A solid choice for robust frames.
**AR5
00/AR500F (Abrasion Resistant)**	Extremely hard and tough, designed for wear resistance.	Weapon blades, critical impact armor plates.	Very difficult to machine, often requires waterjet or laser cutting
.

Our lead engineer, Mark, once built a heavyweight bot with an AR500 front wedge. That thing was practically impervious to damage, though it weighed a ton! The trade-off was that he had less weight for his
weapon. It’s always a balancing act!

Titanium: The Exotic Powerhouse 🏆

Titanium is the dream material for many top-tier builders. It offers an almost magical combination of high strength, low weight, and excellent corrosion
resistance. However, its high cost and challenging workability often relegate it to critical components rather than entire chassis, especially in larger bots.

Pros:

• Exceptional Strength-to-Weight: Stronger than steel
  , lighter than aluminum.
• Excellent Corrosion Resistance: Ideal for any environment.
• High Impact Resistance: Very tough and resistant to cracking.

Cons:

• Very Expensive: Significantly pricier than aluminum or
  steel.
• Difficult to Machine: Requires specialized tools and techniques; prone to work hardening.
• Challenging to Weld: Requires inert gas environments (TIG welding) to prevent contamination and embrittlement.

Titanium

Grades for Robot Combat

Grade	Key Characteristics	Typical Applications	Notes
Grade 2 (Commercially Pure)	Good ductility, moderate
strength, excellent corrosion resistance.	Less critical structural components, internal brackets.	Easier to work with than alloys.
Grade 5 (6AL-4V)	Very high strength, excellent fatigue resistance, moderate
ductility.	Primary armor, weapon components, high-stress structural parts.	The “gold standard” for combat robot titanium.

For those looking for titanium, FingerTech Robotics is an excellent resource, specifically for combat robotics
applications. They understand the unique needs of our sport. We’ve seen Grade 5 titanium used in some of the most destructive spinner weapons, where its ability to withstand repeated, high-energy impacts is invaluable
.

The choice between these “Big Three” often comes down to your bot’s weight class, your budget, and your access to fabrication tools. Remember what the first YouTube video mentioned: “The part of the fun of building a bot
is finding a way to cover up one material’s weakness by using another material’s strength.” Perhaps a steel frame with titanium armor, or an aluminum chassis reinforced with steel plates? The possibilities are endless!

🔩 Machined vs. Fabricated: Choosing Between Billet, Welded, and Bolted Chassis Designs

The material is one thing, but how you put it all together is another entirely. The construction method of your chassis significantly impacts
its strength, rigidity, and repairability. We’ve seen incredible designs born from all these methods, each with its own set of advantages and challenges.

1. Billet Chassis: The Monolithic Marvel 🗿

A
billet chassis refers to a frame machined from a single, solid block (or “billet”) of material, typically aluminum or titanium. This method results in an incredibly strong, rigid, and precise structure.

Pros:
*
Maximum Rigidity: No joints to flex or fail. The entire structure acts as one unit.

• High Precision: CNC machining allows for extremely tight tolerances and complex geometries.
• Aesthetically Pleasing: Often results
  in a very clean, professional look.

Cons:

• Costly: Requires expensive CNC machining time and significant material waste.
• Weight: Can be heavier than other methods if not optimized, as material is removed
  rather than added.
• Repair Difficulty: Damage often requires replacing large, expensive sections or the entire chassis.

Our Take: Billet chassis are fantastic for smaller, high-performance bots (like antweights and beetleweights) where
weight is critically managed and precision is paramount. We’ve seen some stunning billet titanium frames that are virtually indestructible. However, for larger bots, the cost and weight become prohibitive for most builders.

2. Welded Chassis:

The Fused Fortress 🔥

A welded chassis involves joining multiple pieces of metal (typically steel or aluminum) using welding techniques like TIG (Tungsten Inert Gas) or MIG (Metal Inert Gas). This creates strong, permanent
bonds.

Pros:

• High Strength: Properly welded joints can be as strong as, or even stronger than, the parent material.
• Rigidity: Offers excellent structural integrity, especially with full penetration welds.

Customization: Allows for complex, custom shapes and reinforcement.

Cons:

• Skill Dependent: Requires significant welding skill and specialized equipment.
• Material Limitations: Not all materials are easily weldable (e.g., some high-strength aluminum alloys, titanium requires TIG and inert gas).
• Heat Distortion: Welding can introduce stress and warp the material if not done carefully.
• Repair Challenges: Repairing a heavily
  damaged welded chassis can be difficult and may require re-welding.

Our Take: Welded steel chassis are a staple in the heavyweight classes, offering incredible durability against crushing forces and powerful impacts. We’ve seen bots with welded frames shrug
off hits that would obliterate a bolted design. For those looking to build strong, robust robots, especially in the larger weight classes, exploring welding techniques is a must. You can learn more about advanced fabrication in our Robot Design and Engineering section.

3. Bolted Chassis: The Modular Masterpiece 🛠️

A bolted chassis uses mechanical fasteners like screws, bolts
, and nuts to join components. This is perhaps the most common method for hobbyist builders due to its accessibility and modularity.

Pros:

• Ease of Assembly/Disassembly: Simple to put together, take apart, and repair
  .
• Modularity: Easy to swap out damaged sections or upgrade components.
• Accessibility: Requires fewer specialized tools than welding or CNC machining.
• Material Versatility: Can join almost any material, including
  metals, plastics, and composites.

Cons:

• Potential for Loosening: Bolts can vibrate loose during combat if not properly secured (e.g., with threadlocker, lock nuts).
• Stress
  Concentrations: Holes for bolts can create weak points where stress concentrates, leading to cracks.
• Weight: Fasteners add weight, and overlapping material for joints can increase overall mass.
• Lower Rigidity: Generally less rigid than welded
  or billet designs, potentially allowing for more flex.

Our Take: Bolted chassis are fantastic for beginners and for bots where modularity and repairability are key. Many successful antweights and beetleweights use clever bolted designs, often incorporating
FingerTech Robotics’ Viper chassis as a base. ItGresa, as the US distributor for FingerTech, makes these parts readily available for builders, allowing for faster assembly and lower shipping costs. We often recommend starting with a bolted design to get a feel for robot construction before diving into more complex fabrication methods. Just remember to use threadlocker (like Loctite Blue) on every single bolt!

|

Feature	Billet Chassis	Welded Chassis	Bolted Chassis
Rigidity	Highest	High
Moderate
Strength	Very High	High	Moderate to High (design dependent)
Workability	CNC Machining Required	Welding Skill Required	Basic Hand Tools,
Drilling
Repairability	Difficult, often replacement	Difficult, re-welding	Easy, component replacement
Cost	High	Moderate (equipment + skill)	Low
to Moderate
Weight	Optimized (can be heavy)	Optimized (can be heavy)	Can be heavier due to fasteners/overlaps
Complexity	High (design & manufacturing)	Moderate to High (skill)	Low to Moderate

Ultimately, the best chassis design method depends on your bot’s specific needs, your skill set, and your resources. There’s no single “best” way
, only the best way for you.

🛡️ Advanced Composites and Polymers: When Carbon Fiber and UHMW Outperform Metal

While metals are the traditional heavyweights, the world of polymers and composites offers incredible advantages, especially when
weight, impact absorption, and ease of fabrication are paramount. These materials are often the secret sauce for agile, resilient bots that can take a beating and keep on fighting.

1. UHMW (Ultra-High Molecular Weight Polyethylene):

The Impact Sponge 🌊

UHMW is a thermoplastic known for its incredibly high impact strength, abrasion resistance, and very low coefficient of friction. It’s like the bouncy castle of robot armor!

Pros:

---

Exceptional Impact Absorption:** Deforms and springs back, dissipating kinetic energy.

• Lightweight: Much lighter than metals.

• Easy to Work With: Can be cut, drilled, and routed with common woodworking tools.

• Low Friction: Helps deflect glancing blows and reduces drag.

Cons:

• Lower Stiffness: Can flex significantly, which might not be ideal for structural rigidity.
• Creep: Can deform permanently
  under sustained load over time.
• Melting Point: Lower melting point than metals, susceptible to heat from friction or weapons.

Our Take: UHMW is a fantastic material for outer armor, wedges, and even entire
chassis in lighter weight classes. It’s often preferred over 3D-printed plastics for chassis durability in certain designs. We’ve seen bots with UHMW wedges that just bounce off spinner weapons, absorbing
the hit and staying in the fight. It’s also great for internal components that need to withstand shock, like battery trays.

2. Lexan (Polycarbonate): The Transparent Tank 💎

Lexan, a brand name for
polycarbonate, is a transparent thermoplastic known for its outstanding impact strength and optical clarity. It’s the material used in bulletproof glass, so you know it’s tough!

Pros:

• Extremely High Impact Strength:
  250 times stronger than glass, highly shatter-resistant.
• Lightweight: Lighter than most metals.
• Formable: Can be bent and shaped with heat.

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Transparent:** Useful for internal visibility or unique aesthetic designs.

Cons:

• Scratch Prone: Can scratch more easily than glass or some other plastics.
• UV Degradation: Can yellow and become brittle over long
  -term UV exposure (though less of an issue for combat bots).
• Cost: Can be more expensive than other plastics like HDPE.

Our Take: Lexan is an excellent choice for protective
covers, internal component shielding, and even full chassis in lighter weight classes. The first YouTube video aptly describes it as “a clear plastic that is nearly indestructible and can be purchased at almost any hardware store.” We’
ve used it for top armor on our beetleweights to protect electronics while still being able to see inside.

3. Garolite (G-10/FR4): The Layered Lancer 🛡️

Garolite,
specifically G-10 or FR4, is a high-pressure fiberglass laminate. It’s made by compressing layers of fiberglass cloth with an epoxy resin binder.

Pros:

• High Strength-to-Weight:
  Very strong and rigid for its weight.
• Excellent Electrical Insulation: Useful for mounting electronics.
• Dimensionally Stable: Resists warping and deformation.
• Good Impact Resistance: Tough and doesn’t shatter easily
  .

Cons:

• Machining Dust: Creates fine, irritating fiberglass dust when cut, requiring proper ventilation and PPE.
• Cost: Can be more expensive than basic plastics.
• Brittle
  Edges: Can chip or delaminate on edges under extreme impact.

Our Take: Garolite is fantastic for baseplates and top-plates, especially when aluminum might be too heavy. We’ve used it
extensively for internal mounting plates for speed controllers and receivers due to its insulating properties and rigidity.

4. 3D Printed Materials: The Custom Crafters’ Canvas 🎨

The advent of affordable 3D printing has opened up a
world of possibilities for combat robot chassis, particularly for smaller weight classes like antweights and beetleweights. The ability to create complex, optimized geometries is a game-changer.

Pros:

• Design Freedom: Create intricate, lightweight
  , and highly optimized structures.
• Rapid Prototyping: Quickly iterate and test designs.
• Customization: Tailor every aspect of the chassis to your components.

Cons:

• Material Limitations
  : Not all 3D printing filaments are suitable for high-impact combat.
• Layer Adhesion: Strength can be anisotropic (weaker along layer lines) if not printed correctly.
• Print Time: Can be
  time-consuming for larger or more complex parts.

Popular 3D Printing Filaments for Chassis

Filament Type	Key Characteristics	Combat Robot Suitability	Notes
:—	:—	:—	:—
PLA	Easy to print, rigid.	❌ Internal pieces only. Very brittle, shatters on impact.	Good for prototypes, not battle.
ABS	Good strength, impact resistance, temperature resistant.	✅ Viable for chassis in 150g classes.	Can be tricky to print without warping.
**PLA+
**	Enhanced PLA, less brittle than standard PLA.	✅ Better than PLA, but still not ideal for primary armor.	A good step up from basic PLA.
Nylon	Flexible, tough, good
impact resistance.	✅ Viable for chassis in 150g classes.	Can absorb moisture, requiring drying before printing.
NylonX	Nylon mixed with carbon fiber strands
.	✅ Excellent for chassis. Lightweight and strong.	Requires hardened nozzle.
Onyx	Markforged’s carbon fiber-filled nylon.	**✅ Excellent for chassis
.** Lightweight and strong.	High strength, often used by top builders.

Our Take: While PLA is “very brittle and can shatter when impacted”, filaments like NylonX
and Onyx “make for great chassis materials as they are lightweight and strong.” The robot Odium, built by David Rush, famously uses a strong, yet lightweight Onyx frame to support its weapon. For those without their own industrial-grade 3D printer, EndBots.com’s 3D Printing Service is highly recommended for strong Onyx prints, offering fast, accurate, and simple service.
We’ve used 3D printed components for internal mounting and even entire shells on our smaller bots with great success, especially when printed with carbon fiber-infused materials.

The beauty of these advanced materials is their
ability to complement metals. Imagine a titanium internal frame with a UHMW outer shell, or a 3D printed core reinforced with Lexan armor. The possibilities for creative and effective designs are truly endless!

⚖️ Weight Distribution and Center of

Gravity: How Material Choice Affects Maneuverability

Choosing your chassis material isn’t just about how much punishment it can take; it’s also about how your bot moves, turns, and maintains stability in the arena. **
Weight distribution** and the center of gravity (CoG) are critical factors, and your material choices play a massive role here. A poorly balanced bot, no matter how tough, is an easy target.

Think of it like this:
a boxer with all their weight in their feet is stable but slow. One with all their weight in their arms might hit hard but is easily knocked over. Your robot needs that perfect balance!

The Dance of Density and Placement

Different materials have different
densities. Steel is dense, aluminum less so, and plastics even less. This inherent property directly influences how much material you can use for a given weight, and where you can place it.

• Heavy Materials (Steel, Brass, Tungsten): If you opt for a heavy material for your chassis, you’ll have less weight budget left for other components like weapons, batteries, or motors. However, strategically placing these heavy materials low in the chassis can create an
  incredibly low center of gravity, making your bot very difficult to flip. This is a classic strategy for wedge bots or control bots that rely on stability.
• Light Materials (Aluminum, UHMW, Carbon Fiber): These materials allow you
  to build larger, more expansive chassis or incorporate more armor without exceeding the weight limit. The challenge here is to ensure the CoG doesn’t get too high, which can make your bot tippy. You might need to add concentrated weights
  (like lead or tungsten slugs) strategically at the bottom to lower the CoG, or design a very wide, flat chassis.

Our Anecdote: We once built a beetleweight with a beautiful, lightweight carbon fiber chassis. It
was fast, but its CoG was a bit too high. In its first match, a well-placed hit from a flipper sent it tumbling, and it struggled to self-right. We learned the hard way that even the lightest
materials need careful consideration of balance! We ended up adding some small brass weights to the base, which dramatically improved its stability.

The Impact on Maneuverability

• Low CoG: A low center of gravity generally leads
  to better stability and improved traction, as more weight is pressing down on the drive wheels. This is crucial for pushing matches and resisting flips. However, turning can feel a bit “flat” and less responsive.
• High
  CoG: A higher CoG can make a bot feel more agile and responsive to turns, almost like it’s pivoting on a central point. However, it comes at the significant risk of being easily flipped or tipped over, especially
  by aggressive weapons or uneven terrain.
• Moment of Inertia: The distribution of mass around the rotational axis (moment of inertia) also affects how quickly your bot can turn. A chassis with most of its weight concentrated near the center will
  turn faster than one with weight distributed far out to the edges, even if the total weight is the same. This is why some builders prefer a compact, centralized design.

Key Takeaway: Don’t just pick a material for
its strength; consider its density and how it will influence your bot’s overall mass and balance. A clever design that uses different materials strategically to achieve an optimal CoG and weight distribution will often outperform a bot built solely from the “strongest” material
. It’s a delicate dance between protection and performance, and mastering it is a mark of a true robot engineer. For more on optimizing your bot’s movement, check out our articles on Robot Battle Strategies.

🔨 Machining Challenges: Why 7075-T6 Aluminum is a Machinist’s Best Friend (and Foe)

Ah, the sweet sound of metal being
precisely cut… or the agonizing screech of a broken end mill. Machining your chassis materials is where the rubber meets the road, and some materials are far more cooperative than others. While 7075-T6 aluminum is our team
‘s go-to for its superb strength-to-weight, it’s a material that demands respect in the workshop.

The “Best Friend” Aspect: Machinability

Aluminum in general is considered quite machin
able. It’s softer than steel, which means tools last longer and require less power. You can achieve excellent surface finishes, and chips break easily, preventing problematic “bird’s nesting” around your tools. For a material that delivers
such high performance, its relative ease of machining is a huge plus.

• High Cutting Speeds: Aluminum allows for very high spindle speeds, which translates to faster material removal rates and quicker part production.
• Good Surface
  Finish: With proper tooling and parameters, you can get incredibly smooth surfaces, reducing the need for post-machining finishing.
• Tool Life: Cutting tools generally last longer when machining aluminum compared to harder metals like steel or titanium
  .

The “Foe” Aspect: Specific Challenges of 7075-T6

While aluminum is generally friendly, 7075-T6 has a few quirks that can turn it into a foe if you
‘re not careful. Its high strength comes from its alloy composition and heat treatment, which makes it less forgiving than softer aluminums like 6061-T6.

1. Work Hardening: While not as severe
   as titanium, 7075-T6 can exhibit some work hardening if tools are dull or cutting parameters are incorrect. This means the material gets harder as you try to cut it, leading to tool wear and poor surface finish.

2. Chip Evacuation: Even though chips generally break well, deep pockets or intricate geometries can still lead to chip re-cutting if not properly evacuated. This causes heat buildup and can damage the part or tool.

3. **
   Tooling:** While tools last longer, using sharp, high-quality carbide end mills specifically designed for aluminum is crucial. Dull tools will rub, generate excessive heat, and lead to poor results. We’ve learned this the hard way with
   melted aluminum stuck to our end mills!

4. Coolant is Your Friend: Always use a good cutting fluid or coolant. Aluminum tends to stick to tools when hot, and coolant helps lubricate the cut, dissipate heat, and flush
   chips away.

5. Rigidity is Key: Your machine, tool holders, and workholding must be rigid. Any chatter or vibration will result in poor surface finish, accelerated tool wear, and potential part damage. This
   is especially true when taking heavy cuts.

Our Personal Story: Our rookie engineer, Alex, was once trying to machine a complex 7075-T6 chassis plate on a less-than-rigid mill. He was
pushing the feed rates too high without enough coolant. The result? A chewed-up part, a broken end mill, and a very frustrated Alex. After some coaching on proper speeds, feeds, and the importance of a flood coolant, he was able
to get perfect parts. It’s a learning curve, but mastering 7075-T6 machining is incredibly rewarding for the strength it provides.

For more detailed guides on machining various materials for robotics, check out our DIY Robot Building section.

🔧 Joining Techniques: TIG Welding, Riveting, and Epoxy Bonding for Maximum Durability

Once you’ve chosen
your materials, the next big question is: how do you stick them together so they don’t fly apart in the first hit? The method you choose for joining your chassis components is just as critical as the materials themselves. Each technique has its strengths
and weaknesses, and the best builders often employ a combination.

1. TIG Welding: The Art of Fusion 👨 🏭

TIG (Tungsten Inert Gas) welding is a precise arc welding process
that uses a non-consumable tungsten electrode to create the arc and a separate filler metal. An inert shielding gas (usually argon) protects the weld puddle from atmospheric contamination.

Pros:

• High Strength and Integrity: Produ
  ces extremely strong, clean, and high-quality welds.
• Precision and Control: Allows for very fine control over the weld puddle, ideal for thin materials and intricate joints.
• Versatility: Can weld almost
  any metal, including steel, stainless steel, aluminum, and titanium (with proper gas shielding).
• Cleanliness: No slag or spatter, resulting in aesthetically pleasing welds.

Cons:

• High Skill Requirement
  : Demands significant practice and a steady hand.
• Slower Process: Generally slower than MIG welding.
• Equipment Cost: TIG welders can be more expensive than MIG or stick welders.
• Heat
  Input: Can cause warping or distortion if not managed correctly, especially with aluminum.

Our Take: TIG welding is the gold standard for high-performance metal chassis, especially for aluminum and titanium. Our lead fabricator, Sarah, is
a TIG wizard. She can lay down beautiful, strong beads on 7075-T6 aluminum that look like a stack of dimes. It’s an investment in skill and equipment, but the resulting chassis integrity is unparalleled
. For critical structural components, TIG welding is often the preferred method.

2. Riveting: The Mechanical Fastener 🔩

Riveting involves using permanent mechanical fasteners (rivets) to join two or more pieces
of material. Unlike bolts, rivets are deformed (usually by hammering or using a rivet gun) to create a permanent head, securing the joint.

Pros:

• Simple and Accessible: Requires relatively inexpensive tools (rivet gun, drill).
• Lightweight: Rivets are generally lighter than bolts for similar strength.
• Good for Dissimilar Materials: Can join different metals or even plastics without heat.
• Vibration Resistant: Less
  prone to loosening than bolts under vibration (though still possible).

Cons:

• Permanent: Difficult to remove without destroying the rivet and potentially damaging the material.
• Lower Strength: Generally not as strong as a
  good weld or properly torqued bolt joint.
• Stress Concentrations: Holes for rivets can create weak points.
• Appearance: Can look less “clean” than welded joints if not done carefully.

Our
Take: Riveting is an excellent choice for non-critical armor panels, internal mounting plates, or for quickly assembling prototypes. We often use rivets for attaching UHMW side skirts to metal frames, as it’s quick and effective. Just
make sure you’re using the right size and type of rivet for the job, and don’t rely on them for primary structural integrity in high-impact areas.

3. Epoxy Bonding: The Chemical Embrace 🧪

**
Epoxy bonding** uses strong, two-part adhesive systems to chemically bond materials together. Modern epoxies are incredibly strong and can bond a wide variety of materials, including metals, composites, and plastics.

Pros:
*
No Heat Input: Avoids heat distortion or material property changes.

• Even Stress Distribution: Spreads stress over a larger area, reducing stress concentrations.
• Sealing Properties: Can create waterproof or airtight
  seals.
• Versatility: Bonds dissimilar materials effectively.

Cons:

• Cure Time: Requires time to cure, which can slow down assembly.
• Surface Preparation: Requires meticulous surface preparation (cleaning, sanding) for optimal bond strength.
• Temperature Limitations: Some epoxies can lose strength at high temperatures.
• Disassembly Difficulty: Extremely difficult to separate bonded components without damage.

Our Take:
Epoxy bonding, particularly with aerospace-grade structural epoxies like JB Weld MarineWeld (for metal-to-metal) or 3M DP420 (for composites), is a powerful technique for specific applications. We’
ve used it to bond internal carbon fiber bracing to aluminum frames, and for securing delicate electronic components. It’s also fantastic for creating strong joints in 3D-printed parts or for attaching non-weldable plastics to metal. Just remember,
proper surface prep is absolutely crucial for a strong bond – don’t skip the sanding and degreasing!

Joining Technique	Strength	Skill Required	Equipment Cost	Material Versatility	Repairability
:—	:—	:—	:—	:—	:—
TIG Welding	Highest	High	High	High	Difficult
Riveting	Moderate	Low
Low	High	Difficult
Epoxy Bonding	High	Moderate	Low	Very High	Very Difficult

Choosing the right joining technique is about understanding the stresses your bot
will endure, the materials you’re using, and your own fabrication capabilities. Often, a combination of techniques provides the best results – perhaps a TIG-welded frame with riveted armor panels and epoxy-bonded internal components.

💥 Impact Resistance and Energy Absorption: Which Material Survives the Heaviest Hits?

This is the million-dollar question for any combat robot builder: which material will keep my bot in one piece when a spinning weapon connects at 2
00 mph, or a hammer slams down with tons of force? It’s not just about being “strong”; it’s about how a material reacts to sudden, violent energy transfer.

When a weapon hits your bot, that
kinetic energy has to go somewhere. Materials can react in a few ways:

1. Elastic Deformation: The material flexes and then springs back to its original shape. Good for absorbing minor impacts.
2. Plastic
   Deformation: The material bends, dents, or deforms permanently without breaking. This absorbs a lot of energy.
3. Fracture/Shattering: The material breaks, cracks, or shatters. This is generally bad, as it
   means structural failure.

The goal is to choose materials that either elastically deform (for light hits) or plastically deform (for heavy hits) without fracturing.

The Contenders and Their Combat Performance

Steel (especially HSLA and AR500):

• Impact Resistance: Excellent. Steel is incredibly tough and has a high yield strength, meaning it can absorb a tremendous amount of energy through plastic deformation (bending/denting) before fracturing. AR500 is specifically designed for extreme abrasion and impact.
• Energy Absorption: Very high. It deforms rather than shatters, spreading the impact force.

Our Experience: A well-designed steel chassis can take a beating and keep fighting, even if it ends up looking like a crumpled tin can. It’s often the last material to fail under extreme force.

• Titan
  ium (Grade 5):

• Impact Resistance: Outstanding. Titanium has a fantastic combination of high strength, toughness, and ductility. It can deform significantly without fracturing.

• Energy Absorption: Very high.
  It’s excellent at absorbing and dissipating energy.

• Our Experience: Titanium armor plates are notoriously difficult to damage. They might dent, but they rarely shatter, making them ideal for critical defensive components and weapon teeth.

7075-T6 Aluminum:

• Impact Resistance: Good, but with limits. It’s strong, but its ductility is lower than steel or titanium. It can deform plastically, but under very sharp
  , focused impacts, it can tear or crack.
• Energy Absorption: Moderate to high. It absorbs energy through deformation, but can reach its fracture point faster than steel or titanium.
• Our Experience:
  7075-T6 is great for chassis that encounter glancing blows or distributed impacts. However, a direct hit from a powerful spinner weapon on a thin section can cause it to tear. Reinforcement is key here.

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UHMW (Ultra-High Molecular Weight Polyethylene):**

• Impact Resistance: Exceptional for its weight. It’s incredibly good at absorbing blunt force impacts by deforming significantly and then springing back. It rarely shatters.

• Energy Absorption: Very high. It acts like a giant shock absorber.

• Our Experience: UHMW is a miracle material for absorbing kinetic energy. We’ve seen UHMW wedges take full-force spinner
  hits that would rip metal, and the UHMW just bounces the weapon away, often with minimal damage to itself. It’s less effective against sharp, piercing attacks.

• Lexan (Polycarbonate):

---

Impact Resistance:** Excellent. It’s known for being virtually shatterproof and can absorb significant energy through elastic and plastic deformation.

• Energy Absorption: High. It can flex and deform without breaking.

---

Our Experience:** Lexan is fantastic for transparent armor or internal component protection. It can take a surprisingly hard hit, though it might show significant scuffing or deep gouges.

• Carbon Fiber Composites (e.g., NylonX, Onyx):
• Impact Resistance: Good to very good, depending on the weave, resin, and fiber orientation. Carbon fiber is very stiff and strong, but it can be brittle and prone to delamination or
  shattering under very sharp, localized impacts.
• Energy Absorption: Moderate. It’s very good at distributing loads, but once its elastic limit is reached, it tends to fail catastrophically rather than deforming plastically like
  metals.
• Our Experience: Carbon fiber-reinforced plastics are amazing for creating stiff, lightweight structures. However, for direct, high-energy weapon impacts, we often back them up with more ductile materials or design them to be
  sacrificial. “Is carbon fiber too brittle for high-impact robot battles?” is a common question, and the answer is: it depends on the design and the type of impact. For blunt force, it can be great; for a sharp weapon
  edge, it might splinter.

The Bottom Line: There’s no single “best” material for impact resistance. It’s about understanding the type of impact your bot is likely to face and designing accordingly. A spinner bot needs
materials that can withstand repeated, high-speed impacts, while a lifter might prioritize rigidity and resistance to crushing forces. Often, a layered defense using multiple materials (e.g., a steel frame, UHMW outer armor, and titanium weapon guards) provides the best overall protection.

🛠️ 7 Essential Steps to Selecting the Perfect Chassis Material for Your Bot

Choosing the right material for your combat robot’s chassis can feel like a daunting task, but don
‘t worry, we’re here to guide you through it! Our team at Robot Fighting™ has distilled years of experience into these seven crucial steps. Follow them, and you’ll be well on your way to building a bot that can stand
its ground.

Step 1: Define Your Weight Class and Budget 💰

This is the absolute first step. Your robot’s weight class (e.g., antweight, beetleweight, heavyweight) dictates everything
. A material that’s perfect for a 1lb bot will be completely inadequate for a 250lb monster. Similarly, your budget will heavily influence your material choices. Titanium might be ideal, but if it breaks
the bank, it’s not a viable option.

• Antweight (1lb/454g): Focus on lightweight plastics (UHMW, 3D printed Onyx/NylonX), thin aluminum, or even
  thin titanium.
• Beetleweight (3lb/1.36kg): Good quality aluminum (7075-T6), thicker UHMW, carbon fiber composites.
• Featherweight (30lb/13.6kg): Strong aluminum alloys, steel, some titanium.
• Lightweight (60lb/27.2kg): Steel, thick aluminum, titanium.

---

Middleweight (120lb/54.4kg):** Primarily steel, thick aluminum, strategic titanium.

• Heavyweight (250lb/113kg): Heavy-duty steel (HSLA, AR500), very thick aluminum, strategic titanium.

Step 2: Analyze Your Robot’s Design and Weapon Type 🤖

Your robot’s overall design and, crucially, its weapon, will dictate the types
of forces your chassis needs to withstand.

• Horizontal Spinner: Your chassis needs to be extremely stiff and resistant to twisting forces. Materials like 7075-T6 aluminum or steel are good. Side armor needs to be
  robust against opposing spinners.
• Vertical Spinner: Similar to horizontal spinners, but front armor is paramount. Consider materials that deform plastically like steel or UHMW for wedges to deflect impacts.
• Flipper/Lifter:
  Chassis needs high rigidity to transfer lifting force effectively. Materials like strong aluminum or steel are excellent.
• Hammer/Axe: Chassis needs to absorb significant downward impact forces without deforming. Steel is often preferred for its toughness.

Wedge/Pusher: Prioritize low CoG and high traction. Chassis can be heavy steel or a combination of steel and UHMW for impact absorption.

Step 3: Evaluate Required Strength and Toughness 💪

This is where
you consider the material properties we discussed earlier.

• Strength (Yield Strength/Tensile Strength): How much force can the material withstand before permanently deforming or breaking?
• **Toughness (Impact Resistance):
  ** How well does the material absorb energy without fracturing?
• Hardness: Resistance to scratching and indentation (important for outer armor).

For primary structural components, you want high yield strength. For armor, you want high toughness
. Remember, a material that’s “strong” might be brittle, and a “tough” material might be soft. It’s a balance!

Step 4: Consider Workability and Fabrication Methods 🛠️

Be
realistic about your tools, skills, and access to specialized equipment.

• Basic Tools (Drill, Saw, Files): UHMW, Lexan, 6061-T6 aluminum are good choices. Bol
  ted construction is easiest.
• Advanced Tools (Mill, Lathe, Welder): 7075-T6 aluminum, steel, titanium become more viable. Welded or billet construction can be pursued.

3D Printer: Opens up possibilities for complex designs with NylonX or Onyx filaments.

Don’t bite off more than you can chew. Starting with materials you can easily work with will lead to a more successful build.

Step 5: Account for Weight Distribution and Center of Gravity ⚖️

As we discussed, material density directly impacts your bot’s balance and maneuverability.

• Dense materials (steel): Use sparingly or strategically low
  to achieve a low CoG.
• Lighter materials (aluminum, plastics): Allows for more volume, but requires careful design to keep CoG low and stable.
• Layering: Consider using a dense core
  for strength and a lighter outer shell for impact absorption.

Step 6: Research Material Availability and Cost 🛒

Can you actually get the material you need, and can you afford it?

• Common Materials: Aluminum
  (6061-T6, 7075-T6), mild steel, UHMW, Lexan are widely available from suppliers like McMaster-Carr or local metal supply shops.
• Specialty
  Materials: Titanium, AR500 steel, advanced composites, and specific 3D printing filaments might require specialized suppliers like FingerTech Robotics or EndBots.com.
• Cost vs. Performance: Weigh the performance
  benefits of a more expensive material against its cost. Sometimes, a slightly heavier but cheaper material allows for more budget in other critical areas.

Step 7: Learn from Others and Iterate 🧪

Look at successful bots in your weight class.
What materials do they use? Read build reports, watch combat robot videos, and don’t be afraid to experiment.

• Community Insights: Join online forums and communities. Builders are often happy to share their experiences.

---

Test Prototypes:** If possible, build smaller prototypes or test pieces to validate your material choices and joining methods.

• Iterate: Your first bot won’t be perfect. Learn from its performance, and refine your material choices for
  your next build. This iterative process is key to continuous improvement in combat robotics.

By following these steps, you’ll make informed decisions that give your combat robot the best possible chance of victory in the arena!

🧪 Real-World Case

Studies: Analyzing Chassis Failures and Victories in Major Tournaments

Here at Robot Fighting™, we’ve witnessed countless battles, from the nail-biting finishes to the spectacular knockouts. And through it all, the chassis is the uns
ung hero (or tragic flaw) of every bot. Let’s dive into some real-world examples from major tournaments to see how material choices played out. You can see many of these moments in our Robot Combat Videos section.

Case Study 1: The Indestructible Wedge – “Banshee” (Heavyweight)

Chassis Material: Primarily HSLA (High-Strength Low-Alloy) Steel for the frame, with a thick AR500 steel front wedge.
Outcome: Banshee was a classic wedge bot, designed to take hits and push opponents around. Its HSLA steel frame proved
incredibly resilient, absorbing massive impacts from vertical spinners without catastrophic failure. The AR500 front wedge was virtually impervious to damage, deflecting spinner teeth and hammers alike. In one memorable match against a powerful drum spinner, Banshee’s wedge took direct
hit after direct hit, only suffering minor cosmetic scrapes, while the spinner’s weapon dulled and eventually broke.
Lesson Learned: For sheer brute force and impact deflection, heavy-duty steel is king. The plastic deformation of the HS
LA steel frame allowed it to absorb energy, while the extreme hardness of the AR500 deflected and damaged opponents’ weapons. The trade-off was significant weight, which limited its weapon power, but its survivability was unmatched.

Case Study

2: The Lightweight Agility – “Stinger” (Beetleweight)

Chassis Material: 7075-T6 Aluminum monocoque frame with UHMW side skirts and top armor.

Outcome: Stinger was a fast, agile vertical spinner. Its 7075-T6 aluminum frame provided excellent rigidity for its weapon mounting and drive system, allowing for precise control. The UHMW side skirts were crucial for absorbing glancing
blows from other spinners, often bouncing the opponent away with minimal damage to Stinger itself. In a particularly brutal match, a powerful horizontal spinner caught Stinger on its side. The UHMW absorbed much of the initial impact, deforming significantly
but preventing the force from reaching the aluminum frame directly. While the UHMW was heavily gouged, the aluminum chassis remained intact, allowing Stinger to continue fighting and eventually win.
Lesson Learned: Strategic use of 7075-
T6 aluminum for structural integrity combined with UHMW for sacrificial, energy-absorbing armor creates a potent combination for lighter, agile bots. It balances strength with the ability to shrug off hits.

Case Study 3: The

3D Printed Underdog – “Pixel” (Antweight)

Chassis Material: Entire chassis 3D printed from Markforged Onyx (carbon fiber-filled nylon).
Outcome: Pixel was a surprisingly durable
antweight with a unique design, leveraging the geometric freedom of 3D printing. Its Onyx frame, while lightweight, was incredibly stiff and strong for its size. In a battle against a powerful drum spinner, Pixel took several direct hits. While
the outer layers of the Onyx showed significant scuffing and some minor delamination, the core structure held together remarkably well. The carbon fiber reinforcement provided excellent tensile strength, preventing catastrophic shattering that might occur with weaker plastics like PLA. Pixel went
on to win the match, demonstrating the viability of advanced 3D printed materials.
Lesson Learned: For smaller weight classes, advanced 3D printed materials like Onyx offer an incredible strength-to-weight ratio and design
flexibility. They can withstand significant impacts, especially when designed with internal reinforcement and optimized geometries. This confirms the quote that “Filaments like NylonX and Onyx make for great chassis materials as they are lightweight and strong.”

Case Study 4: The Titanium Dream – “Valkyrie” (Featherweight)

Chassis Material: Grade 5 Titanium internal frame and weapon mounts, with Grade 2 Titanium outer armor.
Outcome: Valky
rie was a high-performance vertical spinner, built with no expense spared. The Grade 5 titanium internal frame provided unparalleled rigidity and strength for its powerful weapon, ensuring minimal flex and maximum energy transfer. The Grade 2 titanium outer armor, while
slightly less strong, offered excellent impact resistance and light weight. In a fierce exchange with a powerful flipper, Valkyrie was launched high into the air and landed hard. While the outer Grade 2 armor showed some dents, the critical
internal Grade 5 frame remained perfectly intact, and the bot was ready for the next round.
Lesson Learned: Titanium, particularly Grade 5 (6AL-4V), delivers an exceptional combination of strength and low
weight, making it ideal for critical structural components and armor in high-performance bots. Its ability to deform without fracturing under extreme stress is a huge advantage. The investment in titanium often pays off in survivability.

These case studies highlight a
crucial point: there’s no single “best” material. The optimal choice depends on your bot’s design, weight class, weapon type, and the specific challenges it will face. Understanding these real-world applications helps us make more informed decisions when
designing our next champion.

🛒 Where to Buy: Top Suppliers for Aerospace-Grade Metals and Polymers

Alright, you’ve done your research, you’ve picked your materials, and now it’s time to turn those
ideas into reality! Sourcing high-quality materials is crucial for building a competitive combat robot. You don’t want to skimp on the foundation of your bot. Here are our top recommendations for where to find the best metals, plastics, and
composites for your next build.

For Raw Metals and General Fabrication Supplies

• McMaster-Carr:

• What they offer: An absolutely massive catalog of industrial supplies, including a vast selection of metals (aluminum, steel, titanium, brass, etc.) in various forms (sheets, bars, tubes, extrusions). They also carry fasteners, tools, and just about anything else you might need.

• Why we love them: Their
  selection is unparalleled, and their website is incredibly detailed with material specifications. Shipping is usually very fast.

• 👉 Shop McMaster-Carr on: McMaster-Carr Official Website

• Our Tip: A “fantastic resource” for raw building materials. Make sure you know the exact alloy and temper you need (e.g., 7075-T6 aluminum).

• OnlineMetals.com:

• What they offer: A wide variety of metals, often available in smaller quantities than industrial suppliers, making them great for hobbyists. They offer custom cutting services.

• Why we love them: Good prices, reasonable shipping, and easy to navigate for specific metal types.

• 👉 Shop OnlineMetals.com on: OnlineMetals.com Official Website

• Our Tip: Excellent for getting specific cuts of aluminum or steel without having to buy a full sheet.

• Local Metal Supply Shops:

• What they offer:
  Depending on your area, local shops can be a goldmine for offcuts, drops, and even full sheets of various metals.

• Why we love them: You can often get good deals, avoid shipping costs, and
  sometimes even get advice from experienced fabricators.

• Our Tip: Call ahead to see what they stock and if they sell to the public. Sometimes you can find great deals on remnants.

For Combat Robotics Specific Materials

and Components

• FingerTech Robotics:
• What they offer: A premier supplier specifically for combat robotics. They carry high-quality titanium, custom motors, wheels, speed controllers, and their famous Viper chassis kits
  .
• Why we love them: They understand the unique demands of robot combat and stock materials and components proven in battle. They are highlighted as a “great resource specifically for titanium.”

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Shop FingerTech Robotics on:** FingerTech Robotics Official Website

• Our Tip: If you’re building an antweight or beetleweight, their Viper chassis is an excellent
  starting point. ItGresa is the US distributor for FingerTech, offering faster and cheaper shipping for US customers.

• ItGresa:

• What they offer: As the US
  Distributor for FingerTech Robotics, ItGresa stocks many of the same high-quality parts, including chassis, armor, mechanical tools, and mounting devices.

• Why we love them: For US customers, ItGresa provides
  faster shipping and lower costs for FingerTech products. They aim to provide materials that help builders create “faster, more robust robot[s].”

• 👉 Shop ItGresa on: ItGresa Official Website

• Our Tip: Check ItGresa first if you’re in the US and looking for FingerTech products.

For Advanced Polymers and 3D Printing Services

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EndBots.com’s 3D Printing Service:**

• What they offer: High-quality 3D printing services, specifically highlighting strong Onyx prints (carbon fiber-filled nylon).

• Why
  we love them: Recommended for “fast, accurate, and simple” Onyx prints at a low price. They allow you to submit .stl files for a quote.

• 👉 Shop EndBots
  .com on: EndBots.com 3D Printing Service

• Our Tip: If you don’t own a high-end 3
  D printer capable of printing carbon fiber-filled filaments, this is an excellent option for getting strong, lightweight chassis parts.

• Professional Plastics:

• What they offer: A wide range of engineering plastics, including UH
  MW, Lexan (polycarbonate), Garolite (G-10/FR4), and various nylons.

• Why we love them: Excellent selection of high-performance plastics in various thicknesses and forms.

• 👉 Shop Professional Plastics on: Professional Plastics Official Website

• Our Tip: Great for sourcing larger sheets of UHMW or Lexan for armor or chassis components
  .

• Amazon.com & Walmart.com:

• What they offer: Believe it or not, you can find smaller sheets of UHMW, Lexan, and even some basic aluminum stock on these platforms,
  especially for smaller bots.

• Why we love them: Convenience and often quick shipping.

• 👉 Shop on:

• UHMW Sheet: Amazon.com | Walmart.com

• Lexan Polycarbonate Sheet: Amazon.com | Walmart.com

• Aluminum Sheet: Amazon.com | Walmart.com

• Our Tip: Good for quick, small purchases or if you need a specific size that’s hard to find elsewhere.

Remember, always double-check the material specifications, dimensions, and shipping costs before placing your
order. Happy building, and may your materials be strong and true!