Serviceability

[James H Phelan]

Team,

Michael suggested this as a useful new thread, so....
In addition to Safety, Reliability, and Utility robots should have Serviceability.

"Serviceability measures how easily a system, product, or structure can be maintained, repaired, or utilized. It spans multiple technical and engineering fields, defining how well an asset supports upkeep or fulfills functional operational standards" (Wikipedia via Google AI Overview)

So what are your serviceability tricks? Some of mine are:

Nylon thumbscrews instead of button head hex screws that are a pain to work and strip easily.  Hex head cap screws for more permanent structures - larger socket, respond to either hex wrench or pliers.

Hinged top on Mars Rover with hold up latch

Powerpoles, for disconnects

Velcro fastening squares, cable ties, battery straps

Putting things that need frequent changing, like batteries, in easy to access locations, like on the outside.

Pictures/diagrams of how it's supposed to go back together.

Labels on cables and terminals.

Color coding with heat-shrink tubing and paint pens

Transparency where practical.

Digital library / paper binder of Data Sheets.

Cheat sheets (pasted inside access cover?) "do this first, then this, then that".

Handles for easy mobility

On robot spare storage of critical (fuses) or easy to loose (setscrews) parts.

James

-- 
James H Phelan
"Nihil est sine ratione cur potius sit quam non sit"
Leibniz

[Michael Wimble]

Nice start.

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[Chris Albertson]

My list isn’t long, but here are a few easy-to-do things:

1. I always use brass thread inserts and install them with a soldering iron. This means no loose hex nuts, and the threads last a long time. I’m also so cheap I recycle them. They come out cleanly with a soldering iron. Heat them, then use a screw to pull them out.

2. Whenever plastic parts go together, I add bumps on one part and matching divots on the other so the parts self-align. This costs nothing and makes assembly faster.

3. I always check for screwdriver access in the CAD model. A few times I’ve designed a hole in the structure so a screwdriver can reach a screw head.

4. I’ve made a few custom PCBs that have nothing but connectors on them. Call this a “printed cable.” Why not when JLCPCB offers to make the boards for 20 cents each? Some have an LED or fuse holder on them.   I’ve yet to try having them make a flexible PCB.  This helps with cable clutter.

5. I guess not breaking is a plus for serviceability. I’ve made plastic parts with a 3mm or 4mm threaded hole right through the thinnest section. I print the threads in. Then I’ll put CA glue in the hole and screw in a long screw. It can never be removed. It works like rebar in concrete.

On Aug 10, 2026, at 4:09 PM, 'James H Phelan' via HomeBrew Robotics Club <hbrob...@googlegroups.com> wrote:

Team,

Michael suggested this as a useful new thread, so....
In addition to Safety, Reliability, and Utility robots should have Serviceability.

"Serviceability measures how easily a system, product, or structure can be maintained, repaired, or utilized. It spans multiple technical and engineering fields, defining how well an asset supports upkeep or fulfills functional operational standards" (Wikipedia via Google AI Overview)

So what are your serviceability tricks? Some of mine are:

Nylon thumbscrews instead of button head hex screws that are a pain to work and strip easily.  Hex head cap screws for more permanent structures - larger socket, respond to either hex wrench or pliers.

Hinged top on Mars Rover with hold up latch

Powerpoles, for disconnects….