Tracked Robot Active ESP32 3D Printed

DART Build Tutorial

Complete step-by-step guide to building the DIY Affordable Reliable Tracked robot — from printing parts to deploying with the Android control app.

Quick Downloads: Undercarriage STL Upper Body STL ESP32 Code v1.4.1 Build Video

What You'll Build

DART — DIY Affordable Reliable Tracked — is a fully 3D-printable autonomous tracked robot built around the ESP32 microcontroller and controlled wirelessly via a dedicated Android application over Bluetooth. Every structural component is designed to be printed on a standard FDM 3D printer, making DART accessible to any maker or robotics enthusiast.

This tutorial covers everything: downloading and printing the 3D parts, sourcing hardware and electronics, wiring the schematic, flashing the ESP32, and setting up the mobile control app. Follow the 7 steps in order for a smooth build experience.

Build Overview

Download 3D Files

Get the free DART 3D print packages — Undercarriage and Upper Body STL archives.

Print Components

Print all structural parts using PLA or PETG on a standard FDM printer.

Procure Hardware

Source the fasteners, bearings, and mechanical components from the BOM.

Procure Electronics

Gather the ESP32, motor driver, DC motors, LiPo battery, and wiring components.

Assemble Structure

Assemble the 3D printed undercarriage, install drive components and tracks.

Mount & Wire Electronics

Mount the control electronics and wire following the DART schematic.

Install Mobile App

Download and configure the DART Android control app for Bluetooth operation.

3D Print Files

The DART 3D print package is split into two archives: the Undercarriage (drive system and tracks) and the Upper Body (frame and electronics enclosure). All parts are designed for FDM printing — PLA works well for most components, PETG is recommended for high-stress parts like track links.

Undercarriage Package

Drive wheels, track links, idler rollers, road wheels, and chassis base components.

Drive sprocket (×2)
Track links (×48+)
Road wheels (×8)
Idler wheels (×4)
Chassis side plates (×2)
Motor mounts (×2)

Download UnderCarriageSTL.zip

Upper Body Package

Top frame, electronics bay cover, PCB mounting plate, camera bracket, and antenna mounts.

Main top frame
Electronics bay cover
PCB mounting plate
Camera mount bracket
Antenna bracket
Battery compartment tray

Download UpperBodySTL.zip

Print Settings Tip: Use 3–4 perimeters and 30–40% infill for structural parts. Track links print best lying flat with 100% infill for durability. Recommended layer height: 0.2 mm.

Hardware Bill of Materials

The following fasteners, bearings, and mechanical hardware are required to assemble the DART undercarriage and upper body. All items are standard metric sizes available from hardware stores or online suppliers.

Component	Specification	Qty	Notes
M2.5 Bolt	M2.5 × 8 mm	30	Electronics mounting
M2.5 Bolt	M2.5 × 20 mm	20	Frame assembly
M3 Bolt	M3 × 10 mm	20	Motor mounts, chassis
M3 Bolt	M3 × 20 mm	12	Side plate assembly
M4 Bolt	M4 × 25 mm	8	Drive axle retention
M2.5 Hex Nut	Standard	50	Various joints
M3 Hex Nut	Standard	32	Captive nuts in printed parts
Ball Bearing	8 × 22 × 7 mm (608ZZ)	8	Road and idler wheels
Tension Spring	0.5 × 5 × 20 mm	4	Track tensioners
Steel Axle Rod	Ø8 mm × 120 mm	4	Wheel axles
Lock Washer	M3	20	Vibration prevention

Electronics Bill of Materials

DART uses widely available hobbyist electronics. The ESP32's built-in Bluetooth eliminates the need for a separate radio module, keeping the component count low and the wiring simple.

Component	Specification	Qty	Purpose
ESP32 Dev Board	ESP32-WROOM-32	1	Main controller + Bluetooth
Dual Motor Driver	IBT-2 or L298N	1	Controls both drive motors
DC Brushed Motor	775 DC, 12V, ~10,000 RPM	2	Left & right track drive
LiPo Battery	3S 11.1V, 3000 mAh, 30C+	1	Main power supply
Buck Converter	12V → 5V, 3A (LM2596)	1	Powers ESP32 from battery
Power Switch	XT60 inline rocker switch	1	Main power on/off
XT60 Connectors	Male + Female pair	2	Battery connection
Dupont Wires	Male–Female, assorted	1 set	Signal connections
Heat Shrink Tube	Assorted sizes	1 pack	Wire insulation

Wiring Schematic & Source Code

The DART schematic document and ESP32 source code are available as a free download from the DigInto website. The code includes Bluetooth communication handling, differential drive logic, and configurable speed/direction parameters.

Wiring Schematic

Complete wiring diagram showing ESP32 GPIO pin assignments, motor driver connections, power distribution, and buck converter wiring.

View Schematic

ESP32 Source Code

DART firmware v1.4.1 — Arduino-compatible code for the ESP32. Handles Bluetooth serial, dual-motor differential drive, and app command parsing.

Download DIYUGVV1.4.1.zip

Flashing the ESP32: Upload the code via Arduino IDE. Select ESP32 Dev Module as the board and set the upload speed to 115200 baud. Install the BluetoothSerial library before compiling.

Mobile Control App

The DART Android app connects to the robot over Bluetooth and provides a virtual joystick interface for full directional control. The app is free and available via the DigInto website.