Laser-Cut Wagon for Horse-Shaped Robots

In many robotics projects, having a simple and reliable wagon can be very useful for experiments and demonstrations. The wagon presented in this tutorial is made from 2.8 mm MDF sheets, with all parts precisely cut using a laser cutter. Its design allows it to carry light loads, with dedicated spaces for a battery and a power switch to make it practical for different setups.

I originally designed this wagon so it can be attached to the robots I am building, including horse-shaped robots that I will share in upcoming tutorials. By starting here, you’ll already have a functional, laser-cut wagon that can easily connect to those robots once they are completed. The real fun begins when you combine them—turning this wagon and the robots into an exciting robotic team.

1. Glue – You can use regular liquid craft glue or fast-acting glue (also known as instant adhesive with activator).
2. Small screws – About 1 cm in length, to secure the parts more firmly.
3. Laser-cut parts – The wagon is designed to be cut from 2.8 mm MDF sheets.

Optional (if you want to add power features):

1. Battery holder
2. Power switch
3. Wires
4. Pin headers (female recommended)

To build this wagon, you’ll need to have the design file laser-cut. I’ve already prepared the file, so you can simply download it, take it to a local workshop or maker space, and have the pieces cut for you. Once you have the laser-cut parts, you’ll be ready to assemble the wagon

The first step is to prepare the wagon parts. I’ve already created the design file in AutoCAD, which you can download and use for laser cutting. Take this file to a local workshop, maker space, or any service that offers laser cutting, and ask them to cut the pieces from 2.8 mm MDF sheets. Make sure the material thickness is correct, since the joints are designed very precisely.

After cutting, you should have a complete set of parts ready for assembly. To make things easier, I’ve included photos of the pieces right after cutting. I have also added numbers on the parts. These numbers will guide you during the assembly process, helping you match each piece to its correct position without confusion.

It’s a good idea to carefully check that all parts are included before you start assembling. Keep them organized on a flat surface, and if possible, lightly sand the edges to remove any burn marks from the laser cutter. This will give the wagon a cleaner look and make the assembly smoother.

Once you have all the laser-cut pieces prepared and organized, you’re ready to move on to the next step: putting the wagon together

Once you have all the laser-cut pieces, you can start assembling the main body of the wagon.

1. Part #1 is the floor of the wagon. Place it flat on your workspace.
2. Parts #2 and #3 are the first walls to attach. Apply a thin layer of glue along the corresponding edges of the floor, then carefully fix parts #2 and #3 in place. Make sure they are standing straight and aligned with the base.
3. Next, attach parts #4 and #5 in the same way to complete the rectangular body.

🔹 Tips while gluing:

1. Glue one piece at a time to avoid misalignment.
2. Press the parts gently but firmly so the edges connect neatly.
3. Use just enough glue to hold the parts securely—excess glue may cause a mess.
4. If possible, hold the walls in place with clamps, masking tape, or rubber bands until the glue sets.

By following this order (first parts #2 and #3, then #4 and #5), you’ll get a more accurate fit and a stable body structure. Let the glue dry completely before moving on.

Now that the wagon body is ready, it’s time to install the wheels.

1. Take part #7 (the small round spacer). This piece acts like a washer and should be placed between the wheel and the wagon body. Its purpose is to prevent the wheel from rubbing directly against the body, which would cause friction and make the wheel get stuck.
2. Position the wheel on the outside of the body, with part #7 between the wheel and the wall.
3. Use a small screw (about 1 cm long) to attach the wheel directly to the body. You don’t need a nut—the screw will hold firmly in the MDF.

⚙️ Important notes when tightening the screw:

1. Don’t over-tighten the screw, as this will lock the wheel and stop it from spinning freely.
2. Don’t leave it too loose either, or the wheel will wobble and feel unstable.
3. The screw should be just tight enough so the wheel spins smoothly while staying firmly in place.
4. After attaching each wheel, give it a spin with your hand to check that it rotates freely without resistance or excess play.

One of the useful features of this wagon is that it has dedicated spaces for a battery holder and a power switch. By mounting them directly on the wagon, you don’t have to worry about leaving space for batteries inside your robot. This way, the robot can stay lighter and more compact, while the wagon carries the power source.

This step is optional—depending on your project, you can choose to install the battery holder and switch, or simply leave the wagon as a basic cart.

1. Place the battery holder in the designated area on the wagon and secure it with glue or small screws (depending on the type you use).
2. Mount the power switch in the slot that has been designed for it.

⚡ Wiring tip:

It’s a good idea to attach a female pin header at the end of the battery wires. This way, you can easily connect and disconnect the robot’s motor or control system without dealing with loose wires each time. Using a female header also prevents accidental short circuits (which could happen with exposed male pins).

By following the design layout, you’ll have a neat setup where the wagon itself carries the power system. Later, when you connect your robot, you can simply plug it in and start using it without extra hassle.

With the wagon fully assembled, you can now put it to use by attaching it to your creations. The design was originally made to pair with horse-shaped robots, and in the example images you can see how it looks when connected.

But the wagon isn’t limited to robots—you can get creative! You can attach different types of robots, simple motorized toys, or even just pull it by hand as a cart for small objects. The mounting points make it easy to connect almost anything you’d like.

This flexibility means your wagon can serve as:

1. A trailer for your robots
2. A carrier for small toys
3. A platform for experimenting with sensors, batteries, or other add-ons

Whether you’re building advanced robotics projects or just looking for a fun accessory for your toys, this wagon gives you a sturdy, laser-cut platform to work with.