Re: How to make your robot withstand the beating
 

Know what your resources are. For instance we weld our frame so we build our structure with that in mind, which allows us to escape a level 2 fall off of the pyramid undamaged. Had we built with gusset plates we would have had to beef up our joints more for the same functionality, this isn't a bad thing just something you have to account for during your build. Budget your build time to assure you have time to test. As others have stated build it, test it, break it, redesign, rebuild, repeat, if you get to the point that it doesn't break, make spares because Murphy will find you at competitions and its better to be prepared and not need it then need it and be unprepared. hope this helped.

Re: How to make your robot withstand the beating
 

It honestly depends on your team and how you build. A good rule of thumb is that anything that moves outside of the frame perimeter should be much stronger than anything inside the frame perimeter. For example, we really like to use waterjetted parts. On an intake we might use 1/4" 6061 Al, but on most of our other mechanisms we would use 1/8". This rule of thumb allows you to build a relatively light robot while still maintaining strength in the places you need it. Also, try to get strength from geometry rather than thickness.