From Desktop Dreams to 400kg of Steel and Concrete: Building a High-Rigidity 5-Axis CNC

Go behind the scenes for the development of Torx: the combat robot built by Accu for FightFest 2026, with CNC machining support from Xometry. Explore the journey from the drawing board to the arena, showing how a combat robotics project takes shape, and see how Torx went on to win the official FightFest Championship trophy.

By using agile testing and redesigning a double-sided support to resolve motor deformation and calibration challenges, the TGM student team successfully turned 3D printing waste into high-quality PLA filament.

With Xometry, we have found a manufacturing partner that supports our development philosophy. The ability to quickly and precisely order small batches of parts gives us the freedom to iteratively improve our robots. This flexibility is essential to our innovation process.

In the past, developing non-standard devices was always complicated by the issue of tolerance matching between externally purchased standard parts and custom-machined components. Xometry's one-stop solution perfectly solved this pain point: they not only handled the complex metal 3D printing and sourcing of components but also delivered a finished product that had undergone precision assembly and adjustment. What we received was a functionally ready component that met our precision requirements. This efficient and worry-free delivery experience is exactly what R&D personnel need.

The lessons we learned go far beyond mechanics. We reflect on three key takeaways: people are the ultimate success factor — both the team and its supporters; divide and conquer: breaking the project into subsystems prevents chaos and enables parallel innovation; and industry partners like Xometry are strategic enablers, not just suppliers.

We make the design, upload it to the Xometry Instant Quoting Engine. We see the price and delivery time immediately. Previously, we had to contact four or five different places separately. Now, we receive ready-to-assemble parts from a single channel.

The HTL team from Austria overcame mass distribution and precision challenges to successfully build Cubli, a self-balancing cube powered by reaction wheels and control algorithms.

Our development process begins with extensive brainstorming of potential shapes and sealing methods. 3D printing plays a key role at this stage, allowing us to quickly test different designs before determining the final production materials. Since the final materials are too costly and time-consuming for early prototype stages, we focus on creating small-scale test models in-house, then produce large prototypes through Xometry to ensure convenience and accuracy.

The Horological Society continuously balances its respect for traditional craftsmanship with an openness to modern innovation. One such innovation is the use of 3D printing, which has become an invaluable tool for prototyping clock components in plastic. By sourcing high-quality 3D-printed parts through Xometry, we should be able to test designs efficiently before committing to metal production. This approach allows us to refine intricate mechanisms like gear assemblies with minimal waste and cost.

A student team from University of Maribor developed a stainless steel hose clip for the food and beverage industry, targeting wine and beer fermentation vessels. With Xometry's laser cutting service, they produced 1.5mm thick stainless steel sheet parts featuring elongated teardrop-shaped holes that pinch hoses at two points. The 80 × 45 × 170 mm design requires no lubrication, is food-safe, and grips vessel flanges securely without screws.

Emiel, an aerospace engineering graduate and creator of "The Practical Engineer" YouTube channel, built two magnetic coupling prototypes: magnet-to-magnet and magnet-to-copper using eddy currents. With Xometry's laser cutting service, he sourced copper plates of 3mm and 6mm thickness, discovering that the copper version enables smooth, self-regulating, non-contact torque transfer with 8mm gap capability.

Preparing for the 2026 Air Cargo Challenge, the Fly-Mi team is developing Heméra, a fixed-wing UAV designed for maximum payload transport. This project integrates advanced aerodynamics, structural FEM analysis, and precision-engineered aluminum tooling to create a twin-motor aircraft capable of reaching flight speeds of 35 m/s.