Dane Chaky

Mechanical Engineering | Georgia Tech

Hi! I’m a Mechanical Engineering major at Georgia Tech interested in building aerospace systems. This is my engineering portfolio so far!

Combat Robot Front

What:

  • Designed and manufactured a 3lb vertical spinner combat robot with a 4WD belt-drive system to compete across school (National Robotics Challenge) and professional competitions (Midwest Robot Combat Association, National Havoc Robot League)

How:

  • Used Autodesk Fusion to create a CAD model of the robot
  • Created drawings for an asymmetrical beater bar with a 4″ effective diameter and had it manufactured from S7 tool steel by PCBWay
  • CNC-machined carbon fiber and UHMW Polyethylene components on a Genmitsu PROVerXL 4030 V2 CNC router
  • Printed TPU components on a Bambu P1S 3D printer

Results:

  • Won 1st place at the 2026 National Robotics Challenge, going undefeated without taking any significant damage
Beater Bar 2D Engineering Drawing
Fusion Model
CNC Machining Carbon Fiber Top Plate
Weapon Drawing (first drawing, 2yrs old)
Autodesk Fusion 3D CAD Assembly
2 Bots On The Way To Competition
National Havoc Robot League Fight 1
National Havoc Robot League Fight 2
National Robotics Challenge Fight


Combat Robot Arena

What:

  • Designed and constructed a durable, portable 6’ x 6’ x 2’ combat robot arena using 80/20 aluminum extrusions and two layers of ¼” thick polycarbonate panels with a ¾” air gap between them

How:

  • Modeled the full structure in 80/20’s custom design software, IdeaBuilder
  • Precisely drilled and mounted ⅛” thick 6061 aluminum sheets (flat, strong lower walls) and ½” plywood panels (impact-resistant floor)
  • Laser engraved instructions on ⅛” plywood panels
  • 3D printed custom TPU shims to reduce noise

Results:

  • Donated to my high school robotics club where it has successfully contained high-power combat robot testing
80/20 IdeaBuilder CAD Model
IdeaBuilder Model
Drilling mounting holes in aluminum lower walls
Drilling Holes to Mount Aluminum Lower Walls
Measuring spacing for floor mounting holes
Measuring Spacing for Floor Panel Mounting Holes
Cutting Polycarbonate to Proper Size<
Cutting Polycarbonate to Proper Size
Fixing the Floor Seam
Fixing the Floor Seam
Laser Cutting Instructions
Laser Cutting Instructions

In Progress

Drone 40

What:

  • Making a sub-250g 3.5” quadcopter to carry 3D-printed payloads and record aerial footage

Completed:

  • Modeled the entire drone in Autodesk Fusion
  • Ordered and received all components, except for carbon fiber frame
  • Built a 3D-printed prototype

Currently Working On:

  • Obtaining access to a CNC machine to manufacture the frame from 3mm carbon fiber sheets
Quadcopter Prototype Assembly
Partially-Completed 3D-Printed Prototype