Thin, flexible, capacitive force sensors based on anisotropy in 3D-printed structures

Conductive 3D-printed structures made out of a carbon doped thermoplastic polyurethane (TPU) deposited by an FDM 3D-printer show a high inter-layer contact resistance. Due to this poor resistive coupling capacitive effects between layers become prominent. This effect can be used to create capacitive force sensors by depositing only two thin layers of material. In this paper we investigate the feasibility of such a 3D-printed force sensor. The change in capacitance due to the compression of the material caused by an applied force (0 N to 10 N) is measured using an LCR meter. The presented sensor con- cept has a high potential for implementation in biomedical and soft robotic applications since the sensor is thin and flexible because it is made from soft material

Design Considerations for 3D Printed, Soft, Multimaterial Resistive Sensors for Soft Robotics

Sensor design for soft robots is a challenging problem because of the wide range of design parameters (e.g., geometry, material, actuation type, etc.) critical to their function. While conventional rigid sensors work effectively for soft robotics in specific situations, sensors that are directly integrated into the bodies of soft robots could help improve both their exteroceptive and interoceptive capabilities. To address this challenge, we designed sensors that can be co-fabricated with soft robot bodies using commercial 3D printers, without additional modification. We describe an approach to the design and fabrication of compliant, resistive soft sensors using a Connex3 Objet350 multimaterial printer and investigated an analytical comparison to sensors of similar geometries. The sensors consist of layers of commercial photopolymers with varying conductivities. We characterized the conductivity of TangoPlus, TangoBlackPlus, VeroClear, and Support705 materials under various conditions and demonstrate applications in which we can take advantage of these embedded sensors

Control-based 4D printing: adaptive 4D-printed systems

Building on the recent progress of four-dimensional (4D) printing to produce dynamic structures, this study aimed to bring this technology to the next level by introducing control-based 4D printing to develop adaptive 4D-printed systems with highly versatile multi-disciplinary applications, including medicine, in the form of assisted soft robots, smart textiles as wearable electronics and other industries such as agriculture and microfluidics. This study introduced and analysed adaptive 4D-printed systems with an advanced manufacturing approach for developing stimuli-responsive constructs that organically adapted to environmental dynamic situations and uncertainties as nature does. The adaptive 4D-printed systems incorporated synergic integration of three-dimensional (3D)-printed sensors into 4D-printing and control units, which could be assembled and programmed to transform their shapes based on the assigned tasks and environmental stimuli. This paper demonstrates the adaptivity of these systems via a combination of proprioceptive sensory feedback, modeling and controllers, as well as the challenges and future opportunities they present

Printed, Flexible Lactate Sensors: Design Considerations Before Performing On-Body Measurements.

This work reports the process of sensor development, optimization, and characterization before the transition to on-body measurements can be made. Sensors using lactate oxidase as a sensing mechanism and tetrathiafulvalene as a mediator were optimized for sporting applications. Optimized sensors show linear range up to 24 mM lactate and sensitivity of 4.8 μA/mM which normalizes to 68 μA*cm-2/mM when accounting for surface area of the sensor. The optimized sensors were characterized 3 different ways: using commercially available reference and counter electrodes, using printed reference and counter electrodes, and using a printed reference electrode with no counter electrode. Sensors intended for measuring sweat must be selective in the presence of sweat constituents. Thus, in addition to traditional characterization in pH 7.0 buffer, we characterized sensor performance in solutions intended to approximate sweat. Sensor performance in pH 7.0 buffer solution was not reflective of sensor performance in artificial sweat, indicating that further characterization is necessary between sensor measurement in pH 7.0 buffer and on-body measurements. Furthermore, we performed enzyme activity measurements and sensor measurements concurrently in five different salts individually, finding that while NH4Cl and MgCl2 do not affect enzyme activity or sensor performance in physiologically relevant ranges of salt concentration, NaCl concentration or KCl concentration decreases enzyme activity and sensor current. On the other hand, CaCl2 induced a nonlinear change in sensor performance and enzyme activity with increasing salt concentration

One-shot additive manufacturing of robotic finger with embedded sensing and actuation

A main challenge in the additive manufacturing (AM) field is the possibility to create structures with embedded actuators and sensors: addressing this requirement would lead to a reduction of manual assembly tasks and product cost, pushing AM technologies into a new dimension for the fabrication of assembly-free smart objects. The main novelty of the present paper is the one shot fabrication of a 3D printed soft finger with an embedded shape memory alloy (SMA) actuator and two different 3D printed sensors (strain gauge and capacitive force sensor). 3D printed structures, fabricated with the proposed approach, can be immediately activated after their removal from the build plate, providing real-time feedback because of the embedded sensing units. Three different materials from two nozzles were extruded to fabricate the passive elements and sensing units of the proposed bioinspired robotic finger and a custom-made Cartesian pick and place robot (CPPR) was employed to integrate the SMA spring actuator into the 3D printed robotic finger during the fabrication processes. Another novelty of the present paper is the direct integration of SMA actuators during the 3D printing process. The low melting thermoplastic polycaprolactone (PCL) was extruded: its printing temperature of 70 °C is lower than the SMA austenitic start temperature, preventing the SMA activation during the manufacturing process. Two different sensors based on the piezoresistive principle and capacitive principle were studied, 3D printed and characterized, showing respectively a sensitivity ratio of change in resistance to finger bending angle to be 674.8 Ω∘Angle and a capacitance to force ratio of 0.53pFN . The proposed manufacturing approach paves the way for significant advancement of AM technologies in the field of smart structures with embedded actuators to provide real-time feedback, offering several advantages, especially in the soft robotics domain

Directly Printable Flexible Strain Sensors for Bending and Contact Feedback of Soft Actuators

This paper presents a fully printable sensorized bending actuator that can be calibrated to provide reliable bending feedback and simple contact detection. A soft bending actuator following a pleated morphology, as well as a flexible resistive strain sensor, were directly 3D printed using easily accessible FDM printer hardware with a dual-extrusion tool head. The flexible sensor was directly welded to the bending actuator’s body and systematically tested to characterize and evaluate its response under variable input pressure. A signal conditioning circuit was developed to enhance the quality of the sensory feedback, and flexible conductive threads were used for wiring. The sensorized actuator’s response was then calibrated using a vision system to convert the sensory readings to real bending angle values. The empirical relationship was derived using linear regression and validated at untrained input conditions to evaluate its accuracy. Furthermore, the sensorized actuator was tested in a constrained setup that prevents bending, to evaluate the potential of using the same sensor for simple contact detection by comparing the constrained and free-bending responses at the same input pressures. The results of this work demonstrated how a dual-extrusion FDM printing process can be tuned to directly print highly customizable flexible strain sensors that were able to provide reliable bending feedback and basic contact detection. The addition of such sensing capability to bending actuators enhances their functionality and reliability for applications such as controlled soft grasping, flexible wearables, and haptic devices