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Context: Robotic automation is increasingly critical in modern industry; however, its adoption in small U.S. manufacturing facilities remains limited due to high costs and concerns regarding structural reliability. This paper presents the design, fabrication, and experimental validation of a lightweight, low-cost six-degree-of-freedom (6-DOF) industrial robotic arm intended for precise, low-payload applications such as light material handling and conveyor-based bottle sorting. Carbon fiber–reinforced polymer (CFRP) was selected as the primary structural material to achieve a high stiffness-to-weight ratio while maintaining a compact and efficient design. The robotic arm is engineered for seamless integration with a mobile platform, enhancing deployment flexibility and adaptability across diverse operational environments. Real-time control is achieved through an Android-based graphical interface that computes inverse kinematics and transmits joint commands to an onboard microcontroller via serial communication. The system enables precise control of joint position, velocity, and acceleration. Experimental results demonstrate accurate and reliable performance for small-scale industrial tasks. The mechanical structure was modeled and optimized using Fusion 360, while a user-friendly human–machine interface (HMI) developed in Android Studio enhances operational efficiency and workflow usability. Overall, the robotic arm offers a cost-effective and flexible solution for small manufacturing facilities, effectively bridging the gap between high-performance industrial robotics and lightweight, deployable automation platforms. Experimental results demonstrate reliable system performance, achieving an average trajectory completion time of 13.2 s with a variation of ±0.3 s across repeated trials. The robotic arm supports lightweight handling tasks with consistent repeatability and stable motion execution. Compared to conventional industrial robotic systems, the proposed design significantly reduces system complexity and cost while maintaining acceptable positioning performance for small-scale manufacturing applications.
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