Building a Combat Robot from Scratch
A deep dive into the design, electronics, and software behind our 3lb beetleweight combat robot.
Building a Combat Robot from Scratch
One of the most exciting projects in my engineering classes is building combat robots. This post walks through the full process — from CAD design in Fusion 360 to wiring ESP32 controllers and programming wireless communication.
The Design Phase
Every combat robot starts with weight constraints. In the 3lb beetleweight class, every gram matters. Students learn to balance armor thickness, weapon mass, and drivetrain power within a strict weight budget.
Electronics & Control
We use ESP32 microcontrollers communicating via ESP-NOW for low-latency wireless control. The motor drivers (BTS7960 for drive, BLHeli ESCs for weapons) connect through a custom wiring harness that students design and solder.
Lessons Learned
Combat robotics teaches engineering in a way textbooks can't — when your robot gets hit, you learn about material properties firsthand. When your code has a bug, the robot drives into a wall. The feedback loop is immediate and unforgettable.