Proto Labs lends a hand to robotics entrepreneur

As a self-taught designer, Mr Ware has created robots from a young age, being a prominent name in the European robotics scene since his early teens. He now manages Ranglebox, a niche company in the robotics community, providing small-medium scale robotics products and consultancy to a variety of European clients.

He first came across Proto Labs when looking for local engineering companies, having been contacted to be a contestant on the BBC show, Robot Wars. Needing high specification parts on short lead-times, Mr Ware thought his chance at Robot Wars was just a dream – thankfully this was not the case and work began to create Pulsar.

Mr Ware’s ‘rebel’, Pulsar, is a 110kg fighting robot with attitude. His aim was to create a machine that was impressively practical and intimidating – an objective that has certainly been achieved through its energy transferring drum flywheel and deafening sounds.

With his designs at a progressed stage, Mr Ware needed support to turn his plans into reality, conscious of an ever looming deadline from the BBC. With mere days to go before needing to be ready for a gruelling filming schedule, the Proto Labs team stepped in to offer its support.

To create Pulsar, Proto Labs CNC machined a series of components including the wheel bearing holders and weapon motor mount bulkhead, both integral elements of the robot’s form and function. 3-axis machining of two grades of aerospace aluminium were used to give Mr Ware the properties he needed – 6082-T6 and 7075-T6.

Less than three days after the original order he collected his parts, bolted them into the machine and headed to Glasgow for filming. With several elements left to complete on the robot on arrival, it was a race against time to be ready before the filming and battles commenced.

After considerable effort and little sleep, Pulsar was finally complete at 3.30am on the first day of filming and ready to meet its competitors. Numerous battles ensued and the team managed to reach the final. Mr Ware knew that timing was the determining factor in Pulsar’s development and believed Proto Labs’ quick response time was integral in its success.

“Timing was crucial for me; I only had a few days to go from my designs to needing the high specification parts in my hand and heading up the motorway for filming. It was a very challenging process with so many obstacles – but it was an amazing experience.

“Proto Labs really supported me throughout and I was so pleased to get to the arena with Pulsar ready for action. I’m hoping to ride the wave after Robot Wars and work with Proto Labs in my own business and maybe even in series two.”

Proto Labs www.protolabs.co.uk

Ranglebox www.ranglebox.com