FreeCAD – Part 9: Neck Shaft

In this lesson, we design the neck shaft of the Millie Mini AI robot, creating the vertical structural connector that links the completed torso to the upcoming head assembly.

This lesson focuses on modeling a centered, proportioned support structure that prepares the robot for its face system and upper integration.

Designing the Neck Shaft

We begin by modeling the cylindrical neck shaft that will support the head and tablet enclosure.

This lesson demonstrates how engineers design structural connectors that bridge major robotic assemblies.

The goal here is to create a centered, balanced support column that integrates seamlessly with the torso.

Aligning the Neck to the Body

Before refining proportions, we ensure the neck shaft aligns precisely with the completed torso.

In this lesson, we:

Create the cylindrical neck geometry
Center it on the body’s vertical axis
Adjust proportions for structural balance
Confirm clean transitions between body and neck

This ensures the robot maintains symmetry and structural continuity.

Refining Structural Proportions

With alignment confirmed, we refine the neck’s dimensions and transitions.

In this lesson, we:

Adjust height and diameter for visual balance
Confirm proportional consistency with the torso
Maintain clean part relationships within the assembly
Prepare the top surface for head mounting

This step ensures the neck looks intentional and mechanically sound.

Preparing for Head Integration

Once the neck shaft is finalized, we prepare it for the next stage of the build.

In this lesson, we:

Confirm a clean mounting surface
Ensure proper axis alignment
Finalize the neck-to-body transition
Lock in structural positioning

The robot now has a completed torso and neck structure ready for head integration.

Result So Far

By the end of this lesson, you will have:

Modeled the neck shaft
Aligned it to the torso
Refined structural proportions
Prepared the mounting surface for the head
Completed the robot’s core vertical structure

At this stage, the Millie Mini AI robot now has a defined body-to-head support system.

What’s Next

In the next lesson, we’ll begin building the tablet face enclosure.

We’ll:

Design the tablet housing
Create internal support structure
Define the front display opening
Integrate the enclosure with the neck shaft

This is where the robot begins forming its interactive face system.