Abstract. This study presents the design and stress analysis of mobile robot switchover module (track tensioner), which helps the robot to work in hybrid locomotion mechanism. The track tensioner is a loading and unloading module that helps the locomotion system transformability while robot moves either on wheel or track mechanism. The selection of suitable material for its design, the model is therefore analysed under static loading. It was analysed under static load of 200 N on two selected materials Aluminium alloys Al6061-T6 and Al7075-T6, to determine its mechanical behaviour of models. The results concluded that the material Aluminium alloy Al7075-T6 would be more suitable material for robot design as compared to Aluminium alloy Al6061-T6.