GRACE ROBOTICS

Interaction Booth Fabrication Specifications & BOM

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Project Overview & Constraints Portable, high-end tension fabric interaction booth with a cantilevered canopy. Must pack down into sub-5-foot segments for standard SUV transport.

Strictly prohibited: Fragile plastic accordion/scissor-truss pop-up frames.

1. Base & Anchoring System (Counterweight)

To safely support the cantilevered roof without creating a tripping hazard, the base must be heavy, low-profile, and modular.

Material: 3/8" (approx. 10mm) thick Mild Steel plate.
Finish: Heavy-duty matte black or dark grey powder coat (textured for scratch resistance).
Components:
- 1x Rear Base Plate (curved to match the back wall profile).
- 2x Front "Leg" Plates (extending forward to provide counter-leverage).
Hardware: Countersunk M10 machine screws and heavy-duty steel bridging plates to lock the three sections together perfectly flush with the floor.
Footing: Ultra-thin rubberized anti-slip pads glued to the bottom of the plates to protect venue floors and prevent sliding.

2. Modular Skeleton Framework

This replaces fragile "pop-up" style frames with a rigid, architectural-grade snap-tube system.

Main Tubing: 40mm (1.5") diameter round aluminum extrusion (Alloy 6061-T6 for high strength-to-weight ratio).
Wall Thickness: Minimum 2mm wall thickness to prevent bowing under tension.
Joints (Standard): Internal aluminum sleeving with heavy-duty steel push-button (snap-pin) locks. Bungee cords inside the tubes can be used to keep matching pole segments tethered together for fast assembly.
Cross-Clamps: Machined aluminum saddle clamps to secure the horizontal curved ribs to the vertical upright masts.

3. High-Stress Custom Junctions

Standard push-button joints will fail under the leverage of the overhanging roof. These components must be custom CNC-machined.

The Back "Cantilever" Spigot (4-Way):
- Material: Solid billet aluminum (6061) or machined steel block.
- Design: An internal 90-degree curved elbow with 4 protruding solid spigot pegs (Down, Forward, Left, Right).
- Assembly: The hollow aluminum frame tubes slide over these solid pegs and lock via flush, countersunk hex-drive set screws. No hardware can protrude past the outer diameter of the tube.
The Front Canopy Joint (3-Way):
- Design: A solid internal T-spigot connecting the center load-bearing spine to the left and right front arcs of the halo.

4. Integrated Lighting System

To avoid sticking LED strips on during every setup, the lighting must be segmented and permanently integrated into the aluminum poles.

LED Type: 24V COB (Chip on Board) LED Strips. Crucial: COB LEDs provide a continuous, seamless band of light without the individual "dots" seen in older LED strips, ensuring a premium look through the fabric.
Color Temperature: 4000K or 5000K (Neutral/Daylight White) to flatter facial sensors and provide clear illumination of the robot.
Wiring/Connectors: Pre-soldered, short (2-3 inch) pigtail wires at the end of each modular pole segment using locking JST SM connectors or waterproof barrel jacks.
Power Supply: A low-profile 24V DC power supply hidden within the back wall or mounted directly to the rear steel base plate, with a single black IEC power cable exiting the rear slit of the fabric.

5. Textile Skin (The "Pillowcase")

The fabric must stretch tightly to provide a structural, wrinkle-free finish while isolating the lighting environment.

Material: Heavyweight Dye-Sublimated Stretch Polyester (approx. 240-260 GSM).
Construction: 3-Layer Fabric Sandwich.
- Outer Layer: Brand-color matched stretch polyester.
- Middle Layer: 100% Opaque Blockout layer (black core). Critical for stopping venue spotlights from bleeding through and altering the robot's color temperature.
- Inner Layer (Ceiling/Walls): Matte white or light grey stretch polyester to act as a clean bounce-board/diffuser for the internal LED lighting.
Tailoring: Sewn as a single "pillowcase" that slides entirely over the assembled top canopy and down the back wall.
Closure: A heavy-duty, industrial-grade YKK zipper hidden at the bottom rear edge to pull the entire skin drum-tight over the frame.

6. Transport & Logistics

Everything must fit into an SUV with the seats down (max length 5 feet / 1.5 meters).

Soft Cases: Heavy-duty canvas, wheeled trade-show bags with internal foam dividers to prevent the aluminum poles from scratching each other. Dedicated soft pouches for the folded fabric skin to prevent snagging.
Hard Case: A shallow, custom CNC-cut foam flight case (Pelican style or wooden ATA case) specifically to hold the heavy steel base plates and the custom CNC billet elbows.