This is a roughly 1/7 scale functional model of the mail robot introduced in season 2 of the TV show The Americans. https://uproxx.files.wordpress.com/2017/06/mail-robot.gif
I never planned to make "scale models of office robots from spy shows on FX" into a series, but here we are. https://www.thingiverse.com/thing:920194
I had always planned on catching up on The Americans, but didn't get around to it until last winter ahead of season 5. This project has actually been in the works for the entire past year. I thought that building it around existing electronics would make it easier than the Milton project, so I ordered the absolute cheapest line following robot kit I could find on eBay. It arrived very quickly but the package was missing literally 90% of the advertised components. The seller promised to send the rest, but after a few months of waiting for that to never arrive, I decided to put the project off until this winter. Eventually I ordered another kit which was still extremely cheap but also arrived complete. After assembling, I took measurements and built a rough 3D model of the line following robot, which then allowed me to decide on a scale for the mail robot shell. Initially I wasn't planning to build something quite so big again, but making the mail robot occupy roughly the same footprint as the line following robot would require the proportions to be quite radically altered. I then scaled it up to 1/6 to fit over the line following robot, before stepping down to 1/7 to better fit my printer. The only real deviation I had to make from the shape of the TV mail robot was adding an extra step under the shelves because of the height of the battery pack.
You can see the finished bot in action here: https://www.youtube.com/watch?v=2As6K4clplc
Print one of each part, except for the pins (4), ends and lenses (2 each). For the shelves, you can either print the version that's all one piece or the version separated into flat slot-fit parts (you'll need 4 shelves and 3 vertical dividers) depending on what you think your printer can handle. Only the bottom and the lenses really need support.
I printed everything but the lenses in ABS, and due to the size of the parts there were a few cracks to fix. I really don't love the color either. I think the ideal material would be an almond PET, but this was not available when I was shopping for plastic for this project.
This project is built around an existing line-following robot kit. This is the one I ended up using: https://www.ebay.com/itm/252786280689 It's very cheap, and was easy enough to assemble even without any real instructions. I imagine it may be a knockoff of some name-brand kit. I added some wire to the red LEDs (8 inches from the front, 12 for the rear) so they could be mounted in the right place on the mail robot instead of flush to the board of the line follower.
You'll also need a pair of AA batteries, some thin clear plastic for the sides, and maybe some paper to dress the shelves.
The bottom, top, and ends fit together with built-in pegs and sockets. The "mid" plate fits between the "bottom" and the "base" using the 4 pegs. I glued together the top, bottom, ends and shelves, but left the base as snap-fit. I had to open up the vertical holes in the ends with a drill bit to fit the LEDs through. It's easier to push the LED wires through those holes with the mid plate and base loose, but remember to route the wiring through the big hole in the middle of those. I hot glued the wires in place and the lenses to the LEDs to keep them from slipping back down.
The base has some locating tabs to fit it onto the board of the line-following robot, but it's not an incredibly tight fit. The LED wires should be left long enough so that you can access the line-following robot to change batteries or adjust the potentiometers.
I made the doors out of clear thin packaging plastic (probably PET?). I sort of eyeballed it, taking measurements from the printed model instead of the computer design. You'll want to leave little 1x2mm tabs on one end for the hinges. The "mail" inside is just cut-up paper scraps glued to the shelves.