This report presents the results of a detailed study of mechanical fasteners which were designed to facilitate robotic assembly of structures. Design requirements for robotic structural assembly were developed, taking into account structural properties and overall system design, and four candidate fasteners were designed to meet them. These fasteners were built and evaluated in the laboratory, and the Hammer-Head joint was chosen as superior overall. It had a high reliability of fastening under misalignments of 2.54 mm (0.1 in) and 3 deg, the highest end fixity (2.18), the simplest end effector, an integral capture guide, good visual verification, and the lightest weight (782 g, 1.72 lb). The study found that a good design should incorporate chamfers sliding on chamfers, cylinders sliding on chamfers, and hard surface finishes on sliding surfaces. The study also comments on robot flexibility, sag, hysteresis, thermal expansion, and friction which were observed during the testing.
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