Design of Husky V3

This thesis presents the mechanical design, fabrication, assembly, and experimental validation of Husky V3, a significantly improved iteration of the Husky robot family—a multi-modal ground-aerial platform that addresses multi-locomotion integration through thrust modulation and posture control. The quadruped architecture employs appendage repurposing capable of transitioning between legged and aerial locomotion modes. This work addresses critical compliance and structural deficiencies encountered in Husky Carbon V2, where excessive torso and link flexion compromised flight safety and control stability. The redesign prioritizes structural rigidity through comprehensive component optimization, substantial weight reduction, and integrated wire routing embedded within the leg structure to ensure safe operation and aesthetic presentation. Key innovations include a novel print-in-place (PIP) articulated ankle joint design that eliminates multi-part assembly complexity and bearing installation requirements, replacing them with a single-piece revolute joint. Additionally, custom bearing-embedded motor casing designs facilitate clean wire routing while maintaining structural integrity. Experimental validation demonstrates that these design refinements successfully eliminate structural flexion, reduce system mass for improved thrust-to-weight ratio, and establish Husky V3 as a robust, practical platform for multi-modal locomotion research.