FreeCAD – Part 8: Finished Body

In this lesson, we complete the main body of the Millie Mini AI robot by finalizing the upper cube structure, refining the full body stack, and adding exterior rings that cleanly hide seam transitions between sections.

This lesson focuses on completing the robot’s torso assembly, detailing the internal chambers, and bringing the full body into a clean, structurally finished state before moving on to the neck and face systems.

Upper Cube Completion

We begin by completing the geometry of the top cube, which forms the upper portion of the robot’s body.

This lesson demonstrates how engineers finalize primary structural volumes before integrating upper subsystems like the neck and head assemblies.

The goal here is to ensure the full body stack is aligned, proportioned correctly, and structurally cohesive.

Refining the Full Body Structure

Before adding finishing elements, we verify that all stacked components align cleanly.

In this lesson, we:

Finish the upper cube geometry
Refine alignment between lower and upper body sections
Confirm clean part relationships within the assembly
Ensure consistent spacing and proportions

This ensures the robot’s body is fully defined from base to top.

Adding Seam-Hiding Rings

Once the core body structure is complete, we add circular rings to conceal seam transitions between stacked sections.

In this lesson, we:

Design structural rings
Position them at seam boundaries
Maintain symmetry and clean alignment
Blend structural and aesthetic elements

These rings give the robot a modular, professional appearance while hiding mechanical transitions.

Detailing the Body Chambers

With the exterior transitions refined, we finalize the chamber details within the body.

In this lesson, we:

Define chamber geometry
Refine internal volume spacing
Maintain structural consistency across sections
Ensure a clean and organized internal layout

These chambers establish the internal system spaces that will later house components and subsystems.

Result So Far

By the end of this lesson, you will have:

Completed the upper cube
Refined full body alignment
Added seam-concealing rings
Detailed the body chambers
Fully completed the robot’s torso assembly

At this stage, the Millie Mini AI robot now has a structurally and visually complete body.

What’s Next

In the next lesson, we’ll move upward and begin working on the neck and face assembly.

We’ll:

Design the neck structure
Begin defining head connection geometry
Start shaping the robot’s facial framework

This is where the Millie Mini AI robot transitions from a completed body into a fully expressive upper system.