A Mechanical Structure Design and Simulation-Based Validation of a Novel Compact and Low-Cost 3-DOF Robotic Arm

This paper presents the mechanical design and simulation-based validation of a novel compact and low-cost 3-DOF dual-arm robotic system tailored for space-constrained applications such as rescue robotics. The proposed design achieves a fully folded footprint of 366 × 226.3 × 100 mm through an orthogonal joint configuration and modular structure, while maintaining a hemispherical workspace for each arm. Key innovations include the following: (1) A cost-optimized architecture with only 3 motors per arm (total system cost ~£2000), enabled by hybrid manufacturing (laser-cut acrylic hull and 3D-printed ASA-CF reinforced links with 3740 MPa flexural modulus); (2) a custom Python-based skeleton modeling tool that automates D-H parameter generation and kinematic analysis, supporting rapid design iteration; (3) verified collision-free operation via point cloud analysis, demonstrating successful target grasping (50 mm objects) and dual-arm coordination despite a 5-20 mm deflection tolerance. The system addresses critical limitations in affordable, deployable manipulators, with future work focusing on 3D printing and part manufacturing in industry applications.