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Hexapod Robot
RPI Robotics Club

Introduction and Background

The hexapod robot is an independent project as part of the RPI Robotics Club. The objective is to design and build a hexapod to explore legged locomotion, sensing, and autonomous navigation. Through this project, I aim to develop a comprehensive understanding of the robotics design process—spanning mechanical, electrical, and software components—while investigating the programming and advantages of legged systems over wheeled robots, particularly in navigating uneven terrains with greater stability and adaptability in dynamic environments.

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The hexapod robot provides an opportunity to dive into critical areas such as kinematics, gait programming, sensing, wireless communication, and motion control. Additionally, I plan to integrate sensors like LIDAR and IMUs to enable obstacle detection, terrain mapping, and path planning.

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As this project is ongoing, the following sections provide detailed information on the progress made so far and the current areas of development.

Objectives

  • Design and build a functional hexapod robot capable of smooth and stable basic locomotion, such as moving forward, backward, left, and right.

  • Integrate sensors such as LIDAR and IMUs to enable real-time obstacle detection, terrain mapping, and dynamic path planning.

  • Enable remote control of the hexapod using a wireless joystick or mobile application over short to medium distances.

  • Extend the locomotion capabilities to include climbing and navigating complex terrains, such as rubble, stairs, and steep inclines.

Research and Conceptual Design

Before beginning the design and development of the hexapod robot, I conducted research to understand the fundamental principles of legged locomotion and to learn from existing hexapod designs.

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​Six-Legged Locomotion

To optimize the hexapod’s movement, I explored the mechanics of six-legged locomotion by reviewing online publications that examined how insects like ants and flies move. I also watched videos of various hexapod designs, studying details such as the number of servos used, their movement patterns, and the smoothness of their locomotion.

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Through this research, I discovered that while insects employ a wide range of locomotor strategies, several gaits—such as the tripod gait—are common across many species due to their balance of stability and efficiency.

 

Tripod Gait

The tripod gait is the most common and stable locomotion pattern used by six-legged insects. In this gait, the front and rear legs on one side of the body move synchronously with the middle leg on the opposite side, while the remaining three legs stay in contact with the ground. This creates a “tripod” of support that ensures stability by maintaining a triangular base at all times, making it ideal for moderate speeds and navigating uneven terrain.​

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Bipod Gait

The bipod gait is a dynamically stable locomotion pattern used by insects, where two diagonally opposite legs (e.g., front-left and back-right) remain in contact with the ground while the other four legs are lifted to move forward.

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Compared to the tripod gait, the bipod gait offers lower stability, as the center of gravity must balance over just two points of support. This requires precise coordination and control. However, the bipod gait enables faster movement, making it particularly useful when insects need to flee quickly.

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Researchers have also observed that insects may adopt the bipod gait when adhesion mechanisms, such as sticky pads or claws, fail to engage. In such cases, insects rely on dynamic stability, using their momentum to maintain balance rather than depending on the more stable tripod stance.​​

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Wave Gait

The wave gait is a highly stable locomotion pattern used by six-legged robots and occasionally observed in insects. In this gait, legs move sequentially in a wave-like pattern, with one leg lifting and moving at a time while the other five remain in contact with the ground. This ensures that the center of gravity is consistently supported, providing maximum stability throughout the movement cycle. The deliberate and controlled nature of the wave gait makes it particularly useful for navigating challenging terrains or carrying heavy loads, where balance is critical.

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While the wave gait offers unmatched stability and precision, it comes at the cost of speed, as only one leg moves at a time.

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Sensing and Environmental Awareness​

To enhance the hexapod robot’s ability to navigate and interact with its environment, I explored sensing technologies, focusing primarily on the use of LIDAR (Light Detection and Ranging). LIDAR is a powerful tool for robotic perception, as it provides precise, high-resolution data about the robot’s surroundings by measuring the time it takes for laser pulses to bounce back from objects.

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By integrating LIDAR into the hexapod design, the robot can perform tasks such as obstacle detection, terrain mapping, and path planning. For instance, LIDAR can generate a 2D or 3D map of the environment, allowing the robot to identify obstacles and calculate the safest or most efficient route to its destination. This is particularly useful in cluttered or uneven terrains, where the robot needs to adapt its movements dynamically.

 

In addition to environmental awareness, LIDAR can also enable advanced behaviors like Simultaneous Localization and Mapping (SLAM), where the robot simultaneously maps its surroundings while determining its position within that map.

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While my initial focus is on integrating a basic LIDAR sensor for obstacle detection and navigation, future iterations could involve combining LIDAR data with other sensors, such as IMUs or cameras, to improve accuracy and provide richer environmental awareness.

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Applications and Use Cases

Analyzing existing designs, commonly used gaits, and the overall structure of various hexapods has provided valuable insights into their applications and use cases.

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One of the most immediate applications I am leveraging is their role in education and research. Hexapods are excellent platforms for teaching robotics principles, including gait generation, kinematics, and control systems. They also serve as testbeds for bio-inspired designs, offering a hands-on way to explore advanced locomotion strategies.

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In terms of practical applications, hexapod robots have significant potential in search-and-rescue missions, where their ability to traverse debris, rubble, and other obstacles can be life-saving. Their stability and adaptability across uneven terrain make them ideal for locating survivors or delivering supplies in disaster-stricken areas.

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Hexapods are also valuable in environmental exploration, excelling in navigating challenging terrains like caves, forests, and other areas where wheeled robots face limitations. These robots can also operate in hazardous environments, such as nuclear facilities, pipelines, or chemical plants, to perform inspection and maintenance tasks, reducing the risk to human workers.

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Finally, hexapod robots hold significant promise in space exploration. Their ability to adapt to uneven extraterrestrial terrains makes them ideal for planetary exploration missions, enabling them to traverse rocky surfaces and collect valuable data.

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Takeaways for My Design

To establish initial mobility, I will start with basic gaits, such as the tripod gait, to ensure smooth and stable movement. Once the hexapod achieves reliable locomotion, I plan to experiment with more complex gaits, such as wave and bipod gaits, to improve precision, adaptability, and speed in different scenarios.

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The chassis design will play a critical role in supporting these functionalities. It must provide space for electronics, accommodate servo connections, and ensure durability while remaining lightweight to support the hexapod and maintain efficient movement.

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Tripod_Gait_Robotics.png

Figure 1: Tripod Gait in Ant Locomotion (North Carolina State University).

Figure 2: Walking Pattern of the Insect Tripod Gait (Fumiya lida, 2008).

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Figure 3: Tripod and Bipod Gaits in a Hexapod Robot (EPFL-UNIL).

Figure 4: Wave Gait of a Hexapod Robot (Make Your Pet).

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Figure 5: LIDAR Emitted and Received Pulses (Outsight).

Figure 6: Mobile Robot Mapping with SLAM Algorithm (Robot Brigade).

First Prototype

When designing the first prototype of my hexapod, I aimed to balance cost, complexity, and functionality. Most hexapod designs I researched used three servos per leg (18 servos total), but for my initial build, I chose a simplified approach with two servos per leg (12 servos total). My goal was to test whether the hexapod could still achieve reasonably smooth movement with fewer servos, as this would reduce both component costs and power consumption.

The figure below displays the first CAD design of the hexapod.​​​​

Figure 7: First CAD Design of the Hexapod.

The body of the hexapod consists of two separate plates: the upper and lower frames. These frames are secured together using standard M3 screws, which also serve as attachment points for the legs. The electronics can be housed within the space between the two frames or mounted on top of the upper frame for easy access.

Each hexapod leg is composed of two primary segments: the coxa and the femur.

  • The coxa is the first segment, connecting the leg to the body. It is responsible for forward and backward (lateral) movement.

  • The femur follows the coxa and is responsible for lifting and lowering the leg.

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The coxa servo motor is secured to a blue servo holder, while the femur servo is mounted onto a red servo holder. To transmit motion, white brackets are used to translate the rotational movement of the servos into movement at the corresponding joints, allowing the connected limb segments to articulate as intended. This design ensures that each servo’s torque is directed towards controlling the movement of the hexapod’s legs.​​

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With the initial design complete, I 3D-printed a leg using ABS, selected for its durability and lightweight structure, and proceeded with testing.

Figure 8: First Prototype 3D-Printed Leg.

Lessons Learned from the First Prototype

Through designing and assembling the first hexapod prototype, I gained valuable insights into servo motor mechanics, force transmission, and structural integrity. One of the strengths of this design is its ease of assembly—it requires only one screw type, and all components fit together well. However, when testing the leg movement with active servos, I began noticing several issues.​

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While the coxa mechanism performed effectively, with its servo motion directly controlling the joint without significant force loss, the femur presented challenges. Without the lower red foot-piece attached, the femur moved well, with the servo torque being efficiently transferred to the bracket piece (as seen in Figure 9). However, when the red footpiece was attached, the femur struggled to lift the leg (as seen in Figure 10).

Figure 9: Femur Movement Test.

Figure 10: Leg Movement Test.

There are likely two causes for this issue:

  1. Excess weight on the femur joint, making it difficult for the MG996R servos to generate enough torque.

  2. Inefficiencies in force transfer between the white bracket and the red servo holder. In some cases, the servo continued rotating, but the femur did not fully respond, suggesting flex or play in the connection, reducing force transmission. 

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At this stage, I do not believe that stronger servos are necessary. The coxa joint demonstrates that proper weight distribution allows for effective movement, indicating that the problem is more likely mechanical rather than a lack of torque. To address these issues, I plan to:

  • Refine the mechanical linkage by strengthening the connection between the bracket and servo holder using a revised design.

  • Optimize weight distribution to ensure smoother and more precise motion.

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While the current setup allows for basic movement, it remains jittery and imprecise. To improve control and increase the hexapod’s range of motion, I will increase the servo count to four servos per leg. This will allow each servo to handle a smaller subsection of the leg, reducing strain on individual motors and enabling greater flexibility in movement.

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Naturally, this increase in servos will result in higher power consumption, as more motors will be operating simultaneously. However, this trade-off is manageable through careful power distribution and regulation within the hexapod’s internal electronics. Additionally, while increasing the number of servos raises the overall project cost, I was fortunate to secure funding for the additional servos.

New Design

After conducting additional tests, I identified further areas for improvement in the leg assembly, particularly in connection stability and controlled movement. The original design relied on 3D-printed threads, which loosened over time, introducing play between the servo holder and the white bracket. While the white bracket must rotate to move the next limb, it should only move when actuated by the servo—not due to unwanted external forces like gravity or mechanical resistance.

 

To address these issues, I replaced the 3D-printed threads with heat-set inserts, creating a stronger, more reliable fastening method. This should ensure precise servo control, allowing the white bracket to move only when intended. Additionally, I will incorporate nylon or PTFE washers to reduce friction at the joint, enabling smoother movement. These improvements should enhance the durability, precision, and long-term stability of the leg mechanism. The figure below shows the new CAD model with these changes.

Figure 11: Redesigned Hexapod Robot.

The updated model now defines the leg structure from the hip joint to the foot as follows: the coxa, femur, tibia, and tarsus. Additionally, I have added a cover over the top frame to house the electronics. I am still modifying the design to improve cable routing and will incorporate slits for a future LIDAR sensor to facilitate scanning.

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My next steps are to finalize this design, 3D print a leg, and conduct thorough testing, including its connection to the body. If the performance meets expectations, I will proceed with 3D printing the remaining legs, integrating the electronics, and programming movement.

Design of the Electronics

While designing the updated hexapod body in CAD, I needed precise dimensions of the electronics used to power and control the robot. Instead of relying on messy breadboards, I aimed for a clean, organized layout that would efficiently route cables and manage power distribution. To achieve this, I designed custom PCBs for both the hexapod body and the remote controller.

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Hexapod Body PCB

The body PCB is responsible for powering and controlling the servos, microcontroller, and communication module. It consists of the following components:

  • Dual PCA9685 6-channel 12-bit PWM servo driver boards to control multiple servos.

  • Arduino Nano to act as the main microcontroller.

  • nRF24L01 2.4GHz wireless RF transceiver for wireless communication.

  • Decoupling capacitors and resistors for voltage stability and noise reduction.

Finally, a 3S 3000 mAh 11.1V LiPo battery, 12V/35A switch, and a buck converter are used to power and step down the voltage and current for the PCB to work properly.​​​​

Figure 12: Fritzing Diagram of the Hexapod Body PCB.

Figure 13: Hexapod Body PCB Layout.

Controller PCB

The controller PCB serves as the brain of the remote by integrating the microcontroller and various inputs to communicate with the hexapod.​​​​ It consists of the following components:

  • Arduino Pro Mini to act as the main microcontroller.

  • Dual joysticks for movement.

  • Dual potentiometers for fine-tuned control over movement.

  • Dual switches for additional functionality.

  • nRF24L01 2.4GHz wireless RF transceiver for wireless communication.

  • Voltage regulation to step down power for the nRF24L01 module.

  • Decoupling capacitors for voltage stability and noise reduction.

  • 7.4V battery for power.

Figure 14: Fritzing Diagram of the Controller PCB.

Figure 15: Controller PCB Layout.

To design these PCBs, I referenced online resources such as Aecert Robotics, HowToMechatronics, Electronoobs, and more. The next step is to prototype the PCB circuits on a breadboard to verify their functionality before ordering them for fabrication. This will ensure that all components work as expected and that power distribution, signal integrity, and communication are properly implemented before finalizing the design.

Currently Working On

  • Refining the hexapod CAD design by implementing heat-set inserts to reduce play between joints.

  • Modify the top frame cover to accommodate a 360° LIDAR sensor for future scanning capabilities.

  • Printing and testing a single leg and body before committing to printing all the legs.

  • Assembling all the legs once the initial tests are successful.

  • Prototyping the controller and body PCBs on a breadboard to verify their functionality before ordering them for fabrication.

  • Designing and printing a dedicated holder for the controller.

  • Final assembly of the hexapod, integrating electronics and mechanical components.

  • Programming movement and control for the hexapod.

  • Planning LIDAR integration for future autonomous navigation.

Acknowledgements

I would like to thank the RPI Robotics Club for providing an environment where I could develop and test my ideas, as well as the various resources—both on-campus and online robotics communities—that influenced my research and design. Their insights and tutorials played a crucial role in shaping my approach to developing the hexapod.

© 2025 by Alejandro Begara Criado.

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