Skip to content

5-Axis Machined Parts for a Passive Exoskeleton

RapidDirect 5-axis machined four aluminum lat and deltoid components for a full-body passive exoskeleton built by an independent engineer.

5-Axis Machined Parts for a Passive Exoskeleton
Process
CNC Machining
Materials
Aluminum
Parts
Lat and deltoid components for a full-body exoskeleton
Background

Four Parts That Carry the Load

Andrea Piccinno built a full-body passive exoskeleton in his own time to test how far human-machine support can go. The lat and deltoid components transfer load into the frame, so their surfaces and holes had to line up with the rest of the assembly.

Key challenges
Multiple Machined Faces

Each part is cut from several directions, which multiplies setup error.

The groove needs square internal geometry that 3-axis work cannot reach cleanly.

Angled features had to hold position relative to the load path.

How the Exoskeleton Parts Were Machined

5-axis machining reached the angled and undercut features in fewer setups than 3-axis work would allow.

Prototype Design Review

Prototype Design Review

The part set was checked against the exoskeleton frame before machining.

5-Axis Machining

5-Axis Machining

Angled holes, the U groove and multiple faces were cut with 5-axis access.

Fit Check and Delivery

Fit Check and Delivery

Parts were measured and shipped for assembly into the shoulder structure.

Explore CNC Machining

A Working Passive Exoskeleton

The machined components went into the frame and the suit moved from concept to a wearable prototype.

After delivery

Metal Parts Where It Counts

The four machined pieces carry load into the frame, and holding their geometry kept the assembly aligned.

4 load-bearing parts machined with 5-axis access
A Working Passive Exoskeleton

Have a Similar Manufacturing Challenge?

Share your drawings and project requirements. Our team will help you evaluate the next manufacturing step.

Get an Instant Quote
View All Case Studies