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When I took a featherweight to Robogames as checked luggage, there was no customs problem at all. If you freight it separately, there should be even less of a problem. I found that some of the cheapest rates are from freight companies specialising in excess baggage; just Google "excess baggage shipping" and you will find plenty of leads. From Australia, air freight was cheaper than sea freight and took 5 to 10 days.
I have never freighted a 100 kg heavyweight to San Francisco so I can't say.
I have gone with 2 bags, one containing a 60 pound lightweight robot and the other containing a total of 7 one pound and three pound robots, tools, spares and batteries and have had no problems with American customs. The bags always get opened for inspection (this is done out of my sight, I know because they put a card inside saying the bag has been opened for inspection) and I always include a large notice, right on the top, which says that the suitcase contains robots for competition at Robogames, the date and place of the event, and the fact that there are no wet cell or lithium batteries and that all batteries have been disconnected and terminals taped over. I don't say combat robots. I run my Robogames robots on NiMH batteries to avoid lithium batteries - the airlines all forbid them in luggage.
The notice works well, I do the same. Most airlines do allow Lipo packs, you just have to read the (very) fine print and each airline is a bit different. I flew four packs to the UK on Etihad this year and they didn't have a problem. Their rules state the maximum number of watt-hours for the packs and that they have to be in checked luggage. I took a print-out off their web site when I checked the bags in and they just put a fragile sticker on the case.
We sent 10 heavyweights and 6 feathers over to Singapore and back the other month without an issue. Its cheaper if you can carry anything they consider as dangerous goods (ie batteries of any kind) in your baggage and not ship it. You can take Lipos on a plane with you, there are just limits, but in most cases each person should be able to carry a heavyweights worth.
KLM/Air France have a 160Wh Lithium limit on checked baggage
Each category of robot at Robogames has a 30 machine limit. The 3 pound RC and 220 pound categories are now full. The remaining combat categories as of today are:
Category Current number of entries
150g 4
1 lb 18
1 lb autonomous 0
3 lb autonomous 4
60 lb 16
120 lb 15
As of today the 1 lb RC category is also full. There are 19 each entered in the 60 and 120 lb categories. Lots of space left in the autonomous categories although the Brazilians are signing up some very powerful machines. Am looking for ways to get more armor onto my 1 pounder.
A trip to Robogames is unlikely to disappoint.
Unmakerbot just signed up in the lightweight category - I'm screwed :(
You think? Just another drum spinner in a field that is over half spinners. Or do you know something about it that I don't?
To be fair it is a very very nice drum spinner. Packs hella punch too.