Things You'll Need
Instructions
Preparation
Prepare your building space. It should be well-lit. You will need something to build in or on to prevent missing pieces. A towel will keep pieces from bouncing and make them easy to spot. A low, wide cardboard box will make it easy to keep track of parts. Having several plastic containers on hand may be useful for sorting parts.
Remove the Mindstorms computer brick and set it aside. Place with it the sensor systems, batteries and cables.
Sort the remaining parts by task. Place wheels, axles and tires in their own area. Likewise, place struts and blocks apart. Smaller, moving pieces, such as hinges and pivots, should also be grouped together.
Planning
Determine what kind of robot you would like to build. The Mindstorms instruction book offers several different projects, from simple to complex. First-time builders will probably want to use these instructions. More experienced people can build their own projects from scratch.
Figure out what you would like your robot to do. The Mindstorms kits offer enough parts and sensors to do just about anything. Perhaps you would just like your robot to walk. However, if you want to program a more complex machine, one that reacts to light or picks up certain objects, for instance, other tasks are outlined in the Mindstorms manual.
Look to the online Lego community (see Resources) for ideas. Someone may have already created a design for the project you're envisioning, and you can save time by following that design instead of starting from scratch.
Design
Begin by designing your model before you build it. This is a very important phase. A simple sketch is a good place to start. Lego also offers design software where you can build a model virtually before you do so with actual bricks.
A small mock-up model, using some of the same pieces, can be very useful. Always remember that if you are building a Mindstorms robot, the Mindstorms computer brick must be implemented in the design. This is both the computer brain and the motor that makes the robot move.
Test your design ideas before you build them on a large scale. Determine how you want your robot to move and make sure you have a solid idea of what will go where before you begin construction. This will save you a lot of time in the construction phase.
Construction
The simplest way to build your Mindstorms robot is to follow the step-by-step instructions. The manual offers designs for several robots.
If you choose to build your own custom model, keep these things in mind: The Mindstorms brick must be central and supported, the necessary sensors must be easily accessed, and if the robot is to be self-propelled, the movement mechanism is vital.
First build the support structure for your brick. Do not bury it under excess parts. The primary Mindstorms design is a walking robot where the brick forms the torso. For a vertical robot, this is ideal. For a horizontal crawling or wheeled robot, the brick should be horizontal.
Add the robot's locomotion. This could be two tall walking legs, making a bipedal robot; a series of wheels; or a set of four legs for an animal-like robot. Once the brick is supported, use the driving axles to connect your legs or wheels. This will determine how the rest of the robot comes together. Even if you are building your own custom design, refer to the instructions in the manual for this phase to make sure your vehicle will move properly under its own power.
Do not try to use all the sensors at once. There are many projects you can assemble with a Mindstorms kit, so take your time. Attach one or two sensors to the central brick and then attach them to your model. If you are using a light or visual sensor, it can be located anywhere, but remember that touch sensors should be held out away from the robot on an arm or a probe. Likewise, a sound sensor should not be close to the brick (motor noise will interfere) but extended away from the body or raised up from it.
Finalize Your Robot
Once the brick, the movement system and the sensors are all in place, your robot is almost complete. Add parts to make the design more sleek, or to make the robot look more like something else, such as a vehicle or an animal.
Once the robot is completed, you will need to program the Mindstorms brick. Most of the basic functions that the sensors can accomplish are already programmed in, but you can also attach a USB cable and program the brick through your computer in a variety of languages. If you are still a beginner, you should start with the simple, on-board tasks first.
Test your robot. Don't expect everything to work perfectly right away. The movement mechanisms may need adjusting, or the sensor may need to be moved. In the end, watching a robot you designed do exactly what you designed it to do is an incredibly proud moment.