Beginning with a client meeting and introduction to the concept art.
A methodology of manufacture was decided upon and re-engineering work began to design each individual section, ready for in-house manufacture.
The concept required integration of sheet-steel fabrication, custom vacuum formed ABS panels and OTS components.

A particular focus was given to enforcing the hidden shadow lines from the concept art for the Access Panel components. Various iterations on design and methodology were discussed with the client, over several months.

Sheet steel components for two separate robotic arm units were designed and ordered. These were to be fixed with low-profile bolts & lock-nuts.
Each of these components had to integrate perfectly and fit with OTS components such as medical grade castors, stainless steel handles and Robotic mounting plates.

Transformed Plastix (Victoria), were contracted as specialists to manufacture the necessary vacuum form tooling to create the access panels. Each access panel was poly-welded to a flange, with recessed neodymium magnets. Allowing for the hidden shadow lines and functionality of the Access Panels.

Completed Assembly December 2023.
Airo HaiLo Robot #2, slight variations on mounting plates.
Ongoing supply of the components simplified for the client to assemble in-house, and with the direct supply of completed access panels.