3D Printing in the E.L.A. Project: From Bench Prototypes to Integrated Composites

Why 3D Printing Matters

3D printing is not a hobby tool for E.L.A. — it is a cornerstone capability. Every iteration of design, from v0.1 upward, will require fast cycles of trial, error, and refinement. Traditional machining is slow, costly, and rigid. Additive manufacturing, by contrast, allows us to:

• Prototype Quickly – mounting plates, sensor housings, brackets, and wire guides can be designed and printed in a matter of hours.

• Experiment with Complex Geometries – tendon channels, airflow ducts, and flexible joints that would be impossible to machine can be tested with low-cost plastics.

• Customize Iteratively – each version of E.L.A. can incorporate lessons learned, from improved ergonomics to sensor positioning.

  
  

Phase One: Personal Printing Capability

A reliable personal 3D printer gives independence and speed. Current strong options include:

• Prusa MK4 – Proven open-source ecosystem, robust build quality.

• Bambu Lab X1 Carbon – High speed, auto-calibration, great for iterative design.

• Creality K1 – Budget-conscious, decent speed, strong community support.

Starter materials:

• PLA – cheap, easy to print, best for quick prototypes.

• PETG – more durable, less brittle; useful for mounts and housings.

• ABS / ASA – heat resistant, better for stress-tested parts, but trickier to print.

Skills to build:

• CAD modeling (Fusion 360, FreeCAD, or Onshape)

• Slicing and printer tuning (Cura, PrusaSlicer, Bambu Studio)

• Tolerance design (knowing how much clearance to allow for bolts, sensors, etc.)

Phase Two: Outsourcing for Advanced Builds

Once E.L.A. reaches complexity beyond benchtop plastics, outsourcing becomes necessary:

• Functional Integration – composites printed with wiring channels, embedded sensors, or cooling systems.

• Structural Strength – carbon-fiber reinforced polymers provide stiffness without heavy weight.

• Scalability – while lab printers can output single parts, companies can produce batch runs of reliable subcomponents.

Spotlight: Orbital Composites

Orbital Composites is pioneering robotic 3D printing of composites with the ability to embed wiring, antennas, and fluid channels directly into printed structures. This approach removes the need for secondary assembly steps — the “nervous system” of the robot is integrated during fabrication.

For E.L.A., companies like Orbital point toward a future where:

• Arms or torsos could be printed as single continuous structures with tendons routed internally.

• Cooling or lubrication lines could be built into the frame.

• Antennas and sensor wiring could be sealed inside for durability and sleekness.

Orbital’s work shows us the trajectory: from benchtop PLA prints today to fully integrated composite systems tomorrow.

References

• Prusa Research: https://www.prusa3d.com

• Bambu Lab: https://bambulab.com

• Orbital Composites: https://orbitalcomposites.com