Blip -> Fat Tail, the process of turning a blue Battlebot into a Rat

When you get a ping from the Mark Rober Youtube crew to help out with something, it's generally a good idea to answer.

 

This challenge was a little different for the Seems Reasonable crew though, we had the robot, Blip, but needed to update appearances to fit a storyline with some general direction given. Basically turn innocent blue Blip into an grumpy mechanical Rat named Fat Tail, in a few weeks timespan.

 

Turn this

 

into this

 

I'm sharing this particular thing because it made a few of us in Solidworks have to utilize features we don't touch often, mainly around surface modeling and flexing features to create organic shapes just for a few key details of Ears and a Tail.
And while learning/shaking the rust off of those skills, we were also targeting something that "looked" right, rather than a quantitative performance metric, something else we don't do very often.
 

 

As you can see the Tail took some evolving of the shape until we settled on one, and then we added some features to attach it to the robot and also a split point to make transporting everything easier. 

The final modeling strategy was a structured loft with many controlled cross sections and guide curves, then 3 flex features to bend it into the desired shape.



The Ears were another fun one involving some surface modeling, and the most entertaining part was when it looked like we were 3d printing ham slices. We chose to keep the aesthetic parts being added to the robot as completely TPU 3d printed and color achieved purely via the filament itself, which made creating spares very straightforward, and let us keep the "artistry" in CAD rather than unique hand painted pieces.

 

These are each 3 pieces of TPU glued together

 

                                                                                   And bringing it all together!

                                                                            (the eyes glowing was an us decision)

Chilling before showtime


Lastly a question for readers here, What approach would you take using Solidworks to model a rat tail?