How to Build an Inexpensive Robot Maze

Here's one way to build an inexpensive, reconfigurable maze for robot projects:

The goal was to build a reconfigurable maze or pen for small robots, like Lego Mindstorms or Khepera. The constraints were

Maze walls must be heavy enough not to be displaced by robot collision.
We shouldn't have to do any of our own wood- or machine-shop work.
We should be able to build and dismantle the maze quickly and easily.
We should be able to store the maze components in a small space.

Our solution was to build the maze walls from brick paving stones ("pavers"), around 7x2x4" in size, and the floor from 2' x4' 1/4" oak plywood paneling. The bricks cost around 50 cents apiece from construction/masonry supply stores like ConRock, and the plywood comes in 4x8' sheets at around $24 each from hardware/lumber stores like Lowe's or Home Depot. (If you're not too worried about the smoothness or appearance of your floor, you can get 1/4" plywood for less than half that price.) Lowe's (and probably the other hardware/lumber stores) will cut the plywood down to 2x4' pieces for a very modest fee (first few cuts are free), allowing it to be transported and stored easily.

The main problem with this solution is that bricks are sharp-edged and gritty, and shed flakes and dust. Our solution was to dust each brick off and wrap it in duct tape. The images below show a quick and efficient way of doing this, using ordinary (1.88") and extra-wide (2.82") DuckTape. Here is a breakdown of the estimated cost:

Item Quantity Cost Each Total

Paving bricks 110 $0.50 $55

2' x 4'x 1/4" oak plywood 2 $24 $48

Duct Tape, 2.82" x 60 yd 2 $10 $20

Duct Tape, 1.88" x 55 yd 2 $7 $14

Grand Total $137

Here are some photos:

Materials for cleaning/wrapping brick Wrap edge with extra-wide duct tape Cut tape with single-edge blade

Stand brick on end Fold in edges Lay flat to fold in other side

4 normal-width pieces cover sides A finished brick The robot maze

Item	Quantity	Cost Each	Total
Paving bricks	110	$0.50	$55
2' x 4'x 1/4" oak plywood	2	$24	$48
Duct Tape, 2.82" x 60 yd	2	$10	$20
Duct Tape, 1.88" x 55 yd	2	$7	$14
Grand Total			$137


Materials for cleaning/wrapping brick	Wrap edge with extra-wide duct tape	Cut tape with single-edge blade

Stand brick on end	Fold in edges	Lay flat to fold in other side

4 normal-width pieces cover sides	A finished brick	The robot maze