Version Control for Hardware

Version control is not limited to software. Mechanical systems evolve through iterations, refinements, and design tradeoffs just as code does. Applying structured version control principles to hardware design improves traceability, reduces integration errors, and prevents regression to outdated configurations. A disciplined approach ensures that every change is intentional, documented, and reversible.

Approaches

CAD File Versioning

Modern CAD platforms such as Onshape and Fusion 360 include built-in version history tools. Teams should:

  • Create named versions at stable milestones rather than relying solely on autosave history

  • Use branching when testing alternative design paths

  • Tag versions associated with successful tests or competition builds

  • Lock finalized assemblies to prevent unintended edits

Maintaining a clean version tree allows teams to revert to known stable configurations if experimental changes fail.

Part Numbering and Revision Tracking

Each custom component should have a structured part number and revision identifier. A typical system may include:

  • Assembly code

  • Subsystem identifier

  • Sequential part number

  • Revision letter or number

Revision tracking should reflect functional changes, not cosmetic adjustments. When geometry, tolerances, materials, or interfaces change, increment the revision and document the rationale.

BOM Management

The Bill of Materials must reflect the exact configuration of the robot at any given stage. Maintain:

  • Part numbers and revision levels

  • Quantity per assembly

  • Vendor and sourcing information

  • Material specifications

  • Cost tracking

Each competition release should correspond to a frozen BOM. Changes after freeze should require documented approval and revision updates.

Design Snapshot Documentation

At key milestones, capture full design snapshots including assembly renderings, exploded views, critical dimensions, subsystem interfaces, and electrical routing diagrams. Snapshots serve as reference baselines during troubleshooting and future redesigns.

Best Practices

Commit or Save at Meaningful Milestones

Create named versions at completion of subsystems, after successful testing, before competition freeze, or after major geometry changes. This establishes logical restoration points in the design timeline.

Document Changes in Commit Messages or Design Notes

Each saved version should clearly state what changed, why it changed, expected performance impact, and risks introduced. Clear documentation transforms version history into a traceable engineering record.

Maintain a Release Strategy for Competition Builds

Adopt a structured release cycle including Prototype Release, Alpha Build, Beta Build, and Final Release. Once a release is frozen, restrict modifications to critical fixes only. Maintain a detailed change log documenting all modifications made between competitions.