I read your reply, but I didn’t look at your file. Instead, I went back into the file I posted, and I took a closer look at things. Originally I just looked at your rig and saw the problems I’ve mentioned, I didn’t look at your mesh object. After reading your post, I took another look at the file I posted and the character’s mesh object and it’s modelling.
Stop messing with the new bones you added (but I haven’t looked at), because you are going down the wrong path there. Generally, you have 2 basic ways of rigging stuff in blender - mechanical or organic. Mechanical rigging is for machines that are rigid, like an excavator/back hoe. They are solid and only bend at joint locations. Organic rigging is for living things, humans, trees, flowers and anything else that isn’t rigid.
So a robot like yours should be mechanically rigged. It’s simple and I thought that was what you had. After reading your reply, looking at your screenshots, and messing with my file, I see what is going on.
The shoulder pad shouldn’t bend or deform in any way. Under the shoulder pad I see this:
Which isn’t really a mechanical joint. I would almost want to organically rig that part. Think I would separate the mesh out into several mesh objects for all parts that won’t deform, like the shoulder pads. The highlighted parts of the shoulder above, I would organically rig. All parts like that would be one mesh with an armature modifier on it and weight painted for smooth deformation. The shoulder pad shouldn’t deform, so you parent the mesh object to the bone and it won’t be deformed by the bone, but will move as the bone moves.
Hope that makes sense. You seem to have some knowledge of rigging, where did you learn this at?
If needed, I can cut your robot down and show you an example, but that would take a bit of time…
Randy
PS - I noticed a 2nd bone layer with a couple of bones called ‘Pole Target Finder Arm’
What are those bones for?