Articulated paper robot

What you'll need

• Before cutting, pencil part codes and edge numbers on blank backs. Print all three sheets in one style at 100%. Use 100–160 gsm paper, 0.3–0.5 mm card, glue, clear tape and soft filling. Add 8 split-pin paper fasteners: shaft under 3 mm, head 6–8 mm, legs 8–12 mm. An adult makes the 3 mm holes.

Assembly overview

1. Prepare the parts and fasteners. Before cutting, pencil part codes and edge numbers on blank backs. Print all three sheets in one style at 100%. Use 100–160 gsm paper, 0.3–0.5 mm card, glue, clear tape and soft filling. Add 8 split-pin paper fasteners: shaft under 3 mm, head 6–8 mm, legs 8–12 mm. An adult makes the 3 mm holes.
2. Make strong moving parts. For A1–D2, glue each a/b pair around one traced card core: 16 paper faces, 8 cores. Use R1–R4 to trace 4 card patches; glue them to T1’s blank back, centred on its holes. Let dry. Punch all marked holes to 3 mm, including Q1–Q8.
3. Build elbows and knees. Place B1 over A1’s lower hole, with Q1 between them. Pass a fastener through B1, Q1 and A1; spread its legs behind A1, leaving turning clearance. Repeat A2/B2, C1/D1 and C2/D2 with Q2–Q4. Trial-turn each joint before continuing.
4. Attach four limbs to the torso. Use the remaining 4 fasteners and Q5–Q8 between each upper limb and T1. A1/A2 attach at the upper holes, C1/C2 at the lower holes. Cover exposed fastener tips with small tape patches on their back surfaces; keep tape off shafts and moving layers. Retest all 8 joints.
5. Build the open torso shell. Fold TW1 and TW2 at the dashed lines. TW1 runs along T1’s top and right; TW2 along its bottom and left. Butt all edges without overlap and bridge with 6 mm clear tape outside. The shell is 25 mm deep; leave the entire back open.
6. Fill and close the torso. Add a little loose filling, keeping it away from fasteners. Fit T2 with its printed or colored face outward. Tape all four edges to the rear rim without overlap. The body stays softly filled; do not compress the moving joints or force a packed shell shut.
7. Make and attach the head. Fold NW1 around N1 in edge order 1–4: top, right, bottom, left. Tape the butt joints. Fill lightly, then tape N2 onto the open back. Glue the head’s 40 × 25 mm bottom centrally onto the torso’s 60 × 25 mm top; the neck does not turn.
8. Pose gently. Try small 30–60° joint movements and stop when parts touch. Adjust fastener tightness if needed. Pose the robot lying down or supported; it is not designed to stand unaided. Gently press only the torso centre. Joint friction, durability and squish recovery need a physical build test.