With the help of a company we are working with, we made tremendous progress in the choice of our mechanical architecture. Here is what we settled with:
Each “floor” of the structure is being held to its neighbours by three spacers in an equilateral triangle. The spacers and plates are made of metal (most likely aluminium) and carry the ground from the body (it is being pulled from the arm).
The 12V power is carried through the motor axis which is isolated from the bottom plate.
LED band PCBs are simply held by friction and by their connector. Appropriate holes in the hat and the middle plate are made to fit the PCBs properly and hold them in place.… Read more