If you look at the first prototype of the TNY-360, it looked less like a high-speed quadruped and more like a mobile bowl of spaghetti.

Like many makers, my early build relied heavily on standard development boards and classic Dupont jumper wires. But packing a 12-DOF robot with microcontrollers, sensors, and power distribution into a compact 3D-printed chassis quickly became a nightmare.

Not only was the sheer volume of connectors taking up way too much physical space, but it was also a massive liability. The loose Dupont wires were catching the Electromagnetic Interference (EMI) I talked about in my last log, and every time the robot took a step, the wires threatened to pull loose.

I started hunting for off-the-shelf breakout boards that used JST connectors instead of standard 2.54mm headers. JSTs are lower profile, they lock into place, and they handle the heavy vibrations of a walking robot beautifully. The problem? I couldn't find exactly what I needed for my specific architecture.

Then I had a realization. I had just successfully designed a micro-PCB to fix the servos' potentiometers. Why was I still trying to force off-the-shelf boards to fit my needs? Designing that first tiny board made me realize that custom PCB design is actually much easier and more accessible than I originally thought.

So, instead of fighting the hardware, I designed my own boards.

The Result ?

By designing custom PCBs for the main electronics, I was able to transition the entire robot to low-profile JST connectors. This allowed me to cut and crimp all the wires to the exact required lengths, eliminating the "rats nest" completely.

The inside of the TNY-360's chassis is now incredibly clean, spacious, and vibration-proof.

Even better, I took the opportunity to "idiot-proof" the assembly. I deliberately used different sized JST connectors for different peripherals. For example, sensors and sensors use entirely different pin pitch. Now, when someone builds their own TNY-360, it is physically impossible to accidentally plug a cable into the wrong port and fry the board !

A clean robot is a reliable robot!