Echo: Hardware & Assembly Tutorial

IROS 2025

Artem Bazhenov,

Sergei Satsevich,

Sergei Egorov,

Farit Khabibullin,

Dzmitry Tsetserukou

Mechanical structure

Note: You can find all hardware files, pictures and 3D models in the Echo repository /Hardware folder.

Echo 3D model

Echo features a complex mechanical structure made up of hundreds of components. The setup includes two mechanical arms (though a single arm can be used), which are mounted to a table—we use a welding table—and supported by counterbalances on a framework of aluminum profiles. Each Echo arm is equipped with several standard joints and a joystick. The joint and joystick components are 3D-printed using PLA and TPU92A plastics and assembled with fasteners, couplings, and shafts. The 3D model of Echo uses a hierarchical numbering system to prevent confusion, ensure ease of use, and align with the component lists provided below. 3D model is available on GitHub in /Hardware/3D_models.

ECHO.001.000.000 — Echo right

Echo right exploded

No. Component name Quantity Notes
1ECHO.000.001.000 - Joint base1
2ECHO.000.002.000 - Joint short3
3ECHO.000.003.000 - Joint long2
4ECHO.000.004.000 - Joystick right1
5Shaft 11Length: 50 mm
6Shaft 21Length: 44 mm
7Shaft 31Length: 50 mm
8Shaft 41Length: 56 mm
9Shaft 51Length: 50 mm
10Shaft 61Length: 48 mm
11Shaft 71Length: 20 mm
12Screw M3x12 DIN 9122
13Screw M3x14 DIN 9121
14Screw M3x18 DIN 9123

Each joint is connected to the others via a 4 mm metal shaft and can freely rotate around it. The Joint Base has a rotation limit of 300 degrees, while the other joints are limited to 260 degrees. In Echo, M3 screws serve as stoppers to restrict movement.

Note that in the Echo right and Echo left, the arrangement of the stopping screws on the two upper short joints is different.

Limit screws in the two upper short joints of the Echo right

Limit screws in the two upper short joints of the Echo left

Limit screw in the lower short joint

Limit screw in the lower long joint

Limit screw in the upper long joint

Limit screw in the joystick

ECHO.000.001.000 — Joint base

Joint base exploded

Joint base assembled

The fixed link is attached to the table. It includes the cylindrical ECHO.000.001.002 - Base, which connects to the ECHO.000.001.003 - Bracket. The ECHO.000.001.003 - Bracket is secured to the table using additional mounting hardware (or improvised tools like clamps), with the Commutation PCB mounted on it. The ECHO.000.001.002 - Base holds the ECHO.000.001.004 - Bracket, which serves as the mounting point for the Potentiometer PCB. The Potentiometer PCB is rotated by the ECHO.000.006.000 - Tongue, connected to a shaft. The shaft passes through two bearings inside the ECHO.000.001.005 - Bracket, with its vertical movement restricted by two shaft holders.

Tongue

The ECHO.000.006.000 - Tongue has a flexible TPU92A part, which is secured to the shaft by two plates using two M2 bolts. Finally, two ECHO.000.001.001 - Wall components cover the connector and wires after the Commutation PCB is connected.

No. Component Name Quantity Notes
1ECHO.000.001.001 - Wall2
2ECHO.000.001.002 - Base1
3ECHO.000.001.003 - Bracket2
4ECHO.000.001.004 - Bracket1
5ECHO.000.001.005 - Bracket1
6ECHO.000.006.000 - Tongue1
7ECHO.000.006.001 - Plate1
8ECHO.000.006.002 - Plate1
9ECHO.000.006.003 - Tongue1
10Commutation PCB1
11Bearing 4х7х2.5 MF74ZZ2
12Set screw M3x3 DIN 9162
13Nut M3 Nylon DIN 9854
14Nut M2 DIN 5556
15Screw DIN 7991 M2x10 DIN 9122
16Screw DIN 7991 M2x14 DIN 9124
17Screw DIN 7991 M2x16 DIN 9122
18Screw DIN 7991 M3x10 DIN 9124
19Screw DIN 7991 M3x12 DIN 9128
20Screw DIN 7991 M3x16 DIN 9124
21Screw DIN 7991 M3x22 DIN 9124
22Screw DIN 7991 M3x40 DIN 9122
23Screw M2x10 DIN 9122
24Screw M2x14 DIN 9124
25Screw M2x16 DIN 9122
26Shaft holder2
27Potentiometer PCB1
28Square nut М3 DIN 56219
29Washer 4х9х0.8 DIN 1252
ECHO.000.002.000 - Joint short

Short joint exploded — upview

Short joint exploded — view from below

Short joint assembled — upview

Short joint right assembled — view from below

Typical joint where the axes intersect at 90 degrees. One axis, connected via a coupling, rotates the potentiometer of the previous joint. The other axis, connected to the next joint (which can be a long joint, a joystick, or a short joint), passes through two bearings and rotates the potentiometer mounted on the ECHO.000.001.003 - Bracket using the ECHO.000.006.000 - Tongue.

No. Component Name Quantity
1ECHO.000.002.001 - Bracket1
2ECHO.000.002.002 - Cap1
3ECHO.000.002.003 - Bracket1
4ECHO.000.006.000 - Tongue1
5ECHO.000.006.001 - Plate1
6ECHO.000.006.002 - Plate1
7ECHO.000.006.003 - Tongue1
8Bearing 4х7х2.5 MF74ZZ2
9Coupling1
10Set screw M3x3 DIN 9162
11Nut M3 Nylon DIN 9854
12Nut M2 DIN 5556
13Screw DIN 7991 M2x102
14Screw DIN 7991 M2x162
15Screw DIN 7991 M3x101
16Screw DIN 7991 M3x224
17Screw M2x10 DIN 9122
18Screw M2x16 DIN 9122
19Screw M2x18 DIN 9124
20Screw М3х45 DIN 9122
21Shaft holder2
22Potentiometer PCB1
23Square nut М3 DIN 5626
24Washer 4х9х0.8 DIN 1252
ECHO.000.003.000 — Joint long

Joint long exploded

Joint long assembled

Typical joint where the axes are aligned at 180 degrees. One axis, connected via a coupling, rotates the potentiometer of the previous joint. The other axis, connected to the next joint (which can be a long joint or a short joint), passes through two bearings and rotates the potentiometer mounted on the ECHO.000.003.005 - Bracket using the ECHO.000.006.000 - Tongue.

No. Component Name Quantity
1ECHO.000.003.001 - Bracket1
2ECHO.000.003.002 - Cup1
3ECHO.000.003.003 - Cup1
4ECHO.000.003.004 - Cup1
5ECHO.000.003.005 - Bracket1
6ECHO.000.006.000 - Tongue1
7ECHO.000.006.001 - Plate1
8ECHO.000.006.002 - Plate1
9ECHO.000.006.003 - Tongue1
10Bearing 4х7х2.5 MF74ZZ2
11Coupling1
12Set screw M3x3 DIN 9162
13Nut M3 Nylon DIN 9854
14Nut M2 DIN 5556
15Screw DIN 7991 M2x102
16Screw DIN 7991 M2x162
17Screw DIN 7991 M3x1612
18Screw DIN 7991 M3x81
19Screw M2x10 DIN 9124
20Screw M2x16 DIN 9122
21Screw М3х18 DIN 9121
22Screw М3х45 DIN 9122
23Shaft holder2
24Potentiometer PCB1
25Square nut М3 DIN 56215
26Washer 4х9х0.8 DIN 1252
ECHO.000.004.000 — Joystick right

Joystick right exploded

Joystick right assembled

The right joystick has a button on its LED panel that adjusts ECHO's sensitivity. Inside, an axis extends from the joystick and rotates the potentiometer of the previous joint, while two triggers allow the operator to control the gripper. In the force feedback version by default, one trigger is mounted on a bearing for free movement, and the other is driven by a motor shaft. The motor, located in the handle, drives one of the triggers. The joystick also includes two TPU92A straps for the operator's fingers.

Joystick left

Joystick right

The left joystick has a button on its LED panel that initiates dataset recording. Its internal mechanism is identical to that of the right joystick.

No. Component Name Quantity
1ECHO.000.004.001 - Bracket1
2ECHO.000.004.002 - Grip1
3ECHO.000.004.003 - Cap1
4ECHO.000.004.004 - Table sense1
5ECHO.000.004.005 - Cup1
6ECHO.000.004.006 - Plug1
7ECHO.000.004.007 - Wire protector1
8ECHO.000.004.008 - Wire channel1
9ECHO.000.004.009 - Wire channel1
10ECHO.000.024.004 - Bearing holder1
11ECHO.000.024.005 - Bearing holder1
12ECHO.000.006.000 - Tongue1
13ECHO.000.006.001 - Plate1
14ECHO.000.006.002 - Plate1
15ECHO.000.006.003 - Tongue1
16ECHO.000.014.000 - Trigger1
17ECHO.000.014.001 - Trigger1
18ECHO.000.024.000 - Trigger1
19ECHO.000.024.001 - Trigger1
20ECHO.000.024.002 - Bracket1
21ECHO.000.024.003 - Insert1
22ECHO.000.034.000 - Thimble2
23ECHO.000.034.001 - Thimble D22 mm2
24ECHO.000.034.002 - Insert4
25Commutation PCB1
26Bearing 45х58х71
27Button PBS-15B1
28Coupling3
29Hand Commutation PCB2
30LED 3mm Red_step3
31Set screw M3x3 DIN 9162
32Nut M3 Nylon DIN 9858
33Nut M2 DIN 55514
34Maxon Motor1
35Screw DIN 7991 M2x102
36Screw DIN 7991 M2x128
37Screw DIN 7991 M2x144
38Screw DIN 7991 M2x162
39Screw DIN 7991 M2x64
40Screw DIN 7991 M3x103
41Screw DIN 7991 M3x122
42Screw DIN 7991 M3x144
43Screw DIN 7991 M3x165
44Screw DIN 7991 M3x184
45Screw DIN 7991 M3x252
46Screw DIN 7991 M3x502
47Screw M2x10 DIN 9122
48Screw M2x12 DIN 9128
49Screw M2x6 DIN 9124
50Screw М3х10 DIN 9128
51Screw М3х12 DIN 9122
52Screw М3х20 DIN 9125
53Screw М3х35 DIN 9121
54Screw М3х8 DIN 9124
55Shaft holder2
56Potentiometer PCB1
57Square nut М3 DIN 56232
58Washer 4х9х0.8 DIN 1252
ECHO.000.044.000 — Joystick left
No. Component Name Quantity
1ECHO.000.004.001 - Bracket1
2ECHO.000.004.002 - Grip1
3ECHO.000.004.003 - Cap1
4ECHO.000.044.001 - Table record1
5ECHO.000.004.005 - Cup1
6ECHO.000.004.006 - Plug1
7ECHO.000.004.007 - Wire protector1
8ECHO.000.004.008 - Wire channel1
9ECHO.000.004.009 - Wire channel1
10ECHO.000.024.004 - Bearing holder1
11ECHO.000.024.005 - Bearing holder1
12ECHO.000.006.000 - Tongue1
13ECHO.000.006.001 - Plate1
14ECHO.000.006.002 - Plate1
15ECHO.000.006.003 - Tongue1
16ECHO.000.014.000 - Trigger1
17ECHO.000.014.001 - Trigger1
18ECHO.000.024.000 - Trigger1
19ECHO.000.024.001 - Trigger1
20ECHO.000.024.002 - Bracket1
21ECHO.000.024.003 - Insert1
22ECHO.000.034.000 - Thimble2
23ECHO.000.034.001 - Thimble D22 mm2
24ECHO.000.034.002 - Insert4
25Commutation PCB1
26Bearing 45х58х71
27Button PBS-15B1
28Coupling3
29Hand Commutation PCB2
30LED 3mm1
31Set screw M3x3 DIN 9162
32Nut M3 Nylon DIN 9858
33Nut M2 DIN 55514
34Maxon Motor1
35Screw DIN 7991 M2x102
36Screw DIN 7991 M2x128
37Screw DIN 7991 M2x144
38Screw DIN 7991 M2x162
39Screw DIN 7991 M2x64
40Screw DIN 7991 M3x103
41Screw DIN 7991 M3x122
42Screw DIN 7991 M3x144
43Screw DIN 7991 M3x165
44Screw DIN 7991 M3x184
45Screw DIN 7991 M3x252
46Screw DIN 7991 M3x502
47Screw M2x10 DIN 9122
48Screw M2x12 DIN 9128
49Screw M2x6 DIN 9124
50Screw М3х10 DIN 9128
51Screw М3х12 DIN 9122
52Screw М3х20 DIN 9125
53Screw М3х35 DIN 9121
54Screw М3х8 DIN 9124
55Shaft holder2
56Potentiometer PCB1
57Square nut М3 DIN 56232
58Washer 4х9х0.8 DIN 1252
ECHO.000.024.000 — Trigger

Joystick trigger

Trigger

ECHO.000.124.000 - Trigger without a motor

Trigger without a motor

If force feedback is not required, you can assemble the Echo system without a motor. The only difference is in the design and assembly of the joystick triggers.

ECHO.000.007.000 — Connector protection

Connector protection exploded

Connector protection assembled

The connector protection consists of 3 parts that protect the wire soldering area from external influences and movements.

Note: This table lists components for 1 connector protection. You need 14 connector protections in total — 7 for each Echo arm.

No. Component Name Quantity
1Connector MR30-FB1
2Screw M2x162
3Nut M2 DIN 5554
4Screw M2x10 DIN965A2
5ECHO.000.007.001 - Protector1
6ECHO.000.007.002 - Protector1
7ECHO.000.001.003 - Protector1
Total List of Components for Echo (Two Arms)

Note: The simplest way to create shafts is to cut M4×100 screws. The smooth part of the screw is suitable for use in Echo assembly. Alternatively, you can cut 4-mm steel rods.

No. Component Name Total Quantity
1ECHO.000.000.010 - Bracket to the welding table2
2ECHO.000.001.001 - Wall4
3ECHO.000.001.002 - Base2
4ECHO.000.001.003 - Bracket4
5ECHO.000.001.003 - Protector7
6ECHO.000.001.004 - Bracket2
7ECHO.000.001.005 - Bracket2
8ECHO.000.002.001 - Bracket6
9ECHO.000.002.002 - Cap6
10ECHO.000.002.003 - Bracket6
11ECHO.000.003.001 - Bracket4
12ECHO.000.003.002 - Cup4
13ECHO.000.003.003 - Cup4
14ECHO.000.003.004 - Cup4
15ECHO.000.003.005 - Bracket4
16ECHO.000.004.001 - Bracket2
17ECHO.000.004.002 - Grip2
18ECHO.000.004.003 - Cap2
19ECHO.000.004.004 - Table sense1
20ECHO.000.004.005 - Cup2
21ECHO.000.004.006 - Plug2
22ECHO.000.004.007 - Wire protector2
23ECHO.000.004.008 - Wire channel2
24ECHO.000.004.009 - Wire channel2
25ECHO.000.006.001 - Plate14
26ECHO.000.006.002 - Plate14
27ECHO.000.006.003 - Tongue14
28ECHO.000.007.001 - Protector14
29ECHO.000.007.002 - Protector14
30ECHO.000.014.001 - Trigger2
31ECHO.000.024.001 - Trigger2
32ECHO.000.024.002 - Bracket2
33ECHO.000.024.003 - Insert2
34ECHO.000.024.004 - Bearing holder2
35ECHO.000.024.005 - Bearing holder2
36ECHO.000.034.001 - Thimble D22 mm4
37ECHO.000.034.002 - Insert8
38ECHO.000.044.001 - Table record1
39Screw DIN 7991 M2x68
40Screw DIN 7991 M2x1024
41Screw DIN 7991 M2x1216
42Screw DIN 7991 M2x1416
43Screw DIN 7991 M2x1634
44Screw DIN 7991 M3x88
45Screw DIN 7991 M3x1019
46Screw DIN 7991 M3x1220
47Screw DIN 7991 M3x148
48Screw DIN 7991 M3x1665
49Screw DIN 7991 M3x188
50Screw DIN 7991 M3x2232
51Screw DIN 7991 M3x254
52Screw DIN 7991 M3x352
53Screw DIN 7991 M3x404
54Screw DIN 7991 M3x504
55Screw M2x10 DIN 91220
56Screw M2x12 DIN 91216
57Screw M2x14 DIN 9128
58Screw M2x16 DIN 91216
59Screw M2x18 DIN 91224
60Screw M2x6 DIN 9128
61Screw М3х10 DIN 91216
62Screw М3х12 DIN 9124
63Screw М3х18 DIN 9124
64Screw М3х20 DIN 91210
65Screw М3х35 DIN 9122
66Screw М3х45 DIN 91220
67Screw М3х8 DIN 9128
68Screw M2x10 DIN965A14
69Washer 4х9х0.8 DIN 12526
70Bearing 4х7х2.5 MF74ZZ24
71Bearing 45х58х72
72Button PBS-15B2
73Commutation PCB4
74Connector MR30-FB7
75Coupling13
76Hand Commutation PCB4
77LED 3mm1
78Maxon Motor2
79Nut M2 DIN 555114
80Nut M3 Nylon DIN 98556
81Potentiometer PCB14
82Set screw M3x3 DIN 91620
83Shaft holder28
84Square nut М3 DIN 562201
Name Standard Link
Screw DIN 912 Aliexpress
Screw DIN 7991 Aliexpress
Set screw DIN 916 Aliexpress
Nut M2, M3 DIN 555 Aliexpress
Nut square DIN 562 Aliexpress
Nut Neylon DIN 985 Aliexpress
Coupling - Aliexpress
Thread locker - Aliexpress
Washer DIN 125 Aliexpress
Shaft holder - Aliexpress
Force Finger

Robotiq 2F-85 with force finger

For gripping and force feedback, we integrated an RP-C7.6-LT force sensor into a custom-designed gripper finger on the Robotiq 2F-85. This setup provides force feedback across the entire end effector surface while improving adaptability and protecting the sensor.

The working principle of our mechanism involves a rod, integrated into the pad structure, pressing against the RP-C7.6-LT force sensor through a rubber sheet. Springs return the pad to its original position once the force is released, while guide screws secure it to the structure. The Soft-Touch Anti-Slip Silicone Pad is made from two-component silicone using a 3D-printed PLA mold. This pad prevents slipping, ensures uniform force distribution, and allows gentle gripping of objects. The 3D model of the mold is available on GitHub.

Force finger exploded

Force finger working principle

Note: This table lists components for one force-sensing finger. You need four fingers in total—two for each gripper. A force sensor is required in only one finger per gripper, while the second finger is assembled without a force sensor.

No. Component Name Quantity Link
12222.001.000.000 - Force-Sensing Finger
22222.001.000.001 - Plate1
32222.001.000.002 - Spacer1
42222.001.000.003 - Bracket1
52222.001.000.004 - Plate1
62222.001.000.005 - Plate1
72222.001.001.000 - Pad1
82222.001.001.001 - Pressure Plate1
92222.001.001.002 - Pad1
102222.001.001.003 - Plate1
11Screw DIN 7991 M3x126
12Screw DIN 7991 M3x186
13Screw DIN 7991 M3x204
14Screw DIN 7991 M3x356
15Square nut М322
16force_sensor 20g-1.5kg1
17Spring 6х10х0,44
18 Smooth-On Dragon Skin™ FX-Pro™ Platinum Rubber Silicone 1 Amazon
19 RP-C7.6-LT force sensor 1 Aliexpress
20 Compressed spring 4 Aliexpress
Balancer

Balancer

Balancer in operation — view from the left

Balancer in operation — view from the right

No. Component Name Quantity Link
1 TECNA 9311 (any 0.6-1.5 kg spring balancer will suffice) 4 Aliexpress
ECHO.000.000.010 - Bracket to the welding table

Bracket to the welding table

1111.200.000 - Bracket for camera

Bracket for camera

Electronic components

Main PCB

Side view with components

Top view with components

Top view without components

Bottom view with components

Force sensor PCB

Side view with components

Top view with components

Top view without components

Bottom view with components

Potentiometers SMD (Encoders)

Side view with components

Top view with components

Top view without components

Bottom view with components

Electronics Assembly

Part 1 - Handle switchboard soldering

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Part 2 - Potentiometer soldering

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Part 3 - 14pin flat cable crimp for ADC commutation PCB

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Part 4 - Connector soldering and assembling

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Part 5 - Base switchboard soldering

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Part 6 - Installing the switchboard in the base

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Mechanics Assembly

Part 1 — Assembling the tongue with shaft and shaft holders

1. Temporarily connect the part and TPU using screws.

2. Insert the rod between the plastic part and the TPU component.

3. Clamp the nuts with pliers and tighten the bolts firmly. The rod must not rotate when pressure is applied manually.

4. Slide the shaft holders onto the shaft—one flush against the plastic parts, and the other left loose. Then, lightly tighten the set screws.

Note: Each Echo left/right assembly requires 7 of these tongues (14 per pair) . The dimensions are shown in the 3D model and specifications above.

Part 2 — Installation of square nuts in parts of Joint base — ECHO.000.001.000

Insert the square nuts into their corresponding slots in the parts.

In some areas, you may use small pliers for installation. In others, you can press the nuts down against a flat table surface. For flat sections, bench vises can also be used.

Alternative method:

  • Hold the nut in place using your fingers, pliers, or tweezers
  • Begin threading the screw from the opposite side of the part
  • Remove the screw afterwards

We recommend securing the nuts with adhesive (I used cyanoacrylate with activator), as they may fall out of their slots during assembly.

Part 3 — Mounting the potentiometer PCB - ECHO.000.001.000

Mount the Potentiometer PCB to the bracket using screws and nuts, with a screwdriver and pliers.

Part 4 — Installation of bearing in bracket of Joint base — ECHO.000.001.000s

1. Mount two bearings – one on each side of the bracket's hole. Secure them with adhesive.

2. Insert the tongue-equipped rod through the bearings.

3. Ensure the flexible tongue aligns with the potentiometer's hole.

4. Ensure the tongue rotates freely in the potentiometer when the two brackets are aligned. Do not tighten the bracket screws at this stage.

Part 5 — Assembling Joint Base — ECHO.000.001.000

1. Install the Rod:

  • Insert the rod through the bearings.
  • Place a washer before each bearing.
  • Evenly tighten the set screws while maintaining minimal clearance and ensuring free rotation of the rod.

2. Mount the Potentiometer Bracket: insert the bracket (with potentiometer) into the base and secure with screws.

3. Connect the Brackets: align the bearing bracket’s tongue with the hole in the Potentiometer PCB verifying smooth rotation before securing with two screws.

4. Place the base onto the flat bracket and tighten all screws.

5. Assemble the walls: attach both side panels with screws without full tightening. Confirm correct alignment before final assembly.

Part 6 — Assembling Joint Short — ECHO.000.002.000

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Part 7 — Assembling Joint Long — ECHO.000.003.000

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Part 8 — Installation of square nuts in parts of Joystick — ECHO.000.004.000

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Part 9 — Assembling Trigger — ECHO.000.024.000

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Part 10 — Assembling Joystick — ECHO.000.004.000

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Part 11 — Assembling Echo joints together

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Contact

If you have any questions, please feel free to contact Artem Bazhenov (Telegram | artbazh95@gmail.com) or Sergei Satsevich (Telegram | sazewar@gmail.com).