A 3D printed monolithic soft gripper with adjustable stiffness

Soft robotics has recently gained a significant momentum as a newly emerging field in robotics that focuses on biomimicry, compliancy and conformability with safety in near-human environments. Beside conventional fabrication methods, additive manufacturing is a primary technique to employ to fabricate soft robotic devices. We developed a monolithic soft gripper, with variable stiffness fingers, that was fabricated as a one-piece device. Negative pressure was used for the actuation of the gripper while positive pressure was used to vary the stiffness of the fingers of the gripper. Finger bending and gripping capabilities of the monolithic soft gripper were experimentally tested. Finite element simulation and experimental results demonstrate that the proposed monolithic soft gripper is fully compliant, low cost and requires an actuation pressure below -100 kPa

3D Printing of a Thin-Wall Soft and Monolithic Gripper Using Fused Filament Fabrication

Soft materials have been incorporated in the design of robotic systems particularly as a damper, cover or contact pads. With the emergence of soft robotics, which focuses on robotic devices partially or entirely made of soft materials, robotic systems with high deformability, conformability and biomimicry can be realized. By pushing the limits of low cost 3D printing, this study focuses on designing and fabricating low cost, thin-wall, airtight, soft and monolithic fingers and a fully compliant gripper as a one-piece robotic device. Fused filament fabrication method was used to 3D print the soft monolithic fingers and gripper. Their bending and blocking force capabilities were experimentally evaluated. The proposed method can be used not only to 3D print fully compliant inflatable soft robots using a low cost additive fabrication method but also all-in-one piece soft robots ready to operate out of one-step fabrication such as soft grippers and mobile assistive devices with major advantages of low cost, underactuated, and more importantly compliant and highly conformable

3D printed pneumatic soft actuators and sensors: their modeling, performance quantification, control and applications in soft robotic systems

Continued technological progress in robotic systems has led to more applications where robots and humans operate in close proximity and even physical contact in some cases. Soft robots, which are primarily made of highly compliant and deformable materials, provide inherently safe features, unlike conventional robots that are made of stiff and rigid components. These robots are ideal for interacting safely with humans and operating in highly dynamic environments. Soft robotics is a rapidly developing field exploiting biomimetic design principles, novel sensor and actuation concepts, and advanced manufacturing techniques. This work presents novel soft pneumatic actuators and sensors that are directly 3D printed in one manufacturing step without requiring postprocessing and support materials using low-cost and open-source fused deposition modeling (FDM) 3D printers that employ an off-the-shelf commercially available soft thermoplastic poly(urethane) (TPU). The performance of the soft actuators and sensors developed is optimized and predicted using finite element modeling (FEM) analytical models in some cases. A hyperelastic material model is developed for the TPU based on its experimental stress-strain data for use in FEM analysis. The novel soft vacuum bending (SOVA) and linear (LSOVA) actuators reported can be used in diverse robotic applications including locomotion robots, adaptive grippers, parallel manipulators, artificial muscles, modular robots, prosthetic hands, and prosthetic fingers. Also, the novel soft pneumatic sensing chambers (SPSC) developed can be used in diverse interactive human-machine interfaces including wearable gloves for virtual reality applications and controllers for soft adaptive grippers, soft push buttons for science, technology, engineering, and mathematics (STEM) education platforms, haptic feedback devices for rehabilitation, game controllers and throttle controllers for gaming and bending sensors for soft prosthetic hands. These SPSCs are directly 3D printed and embedded in a monolithic soft robotic finger as position and touch sensors for real-time position and force control. One of the aims of soft robotics is to design and fabricate robotic systems with a monolithic topology embedded with its actuators and sensors such that they can safely interact with their immediate physical environment. The results and conclusions of this thesis have significantly contributed to the realization of this aim

Characterization Of Commercially Available Conductive Filament And Their Application In Sensors And Actuators

The primary aim of this study is to contribute to the field of additives that would enable the fabrication of electrical sensors and actuators completely via Material Extrusion based Additive Manufacturing (MEAM). The second aim of the study is to provide the necessary characterization to facilitate the development of applications that predicts electrical part performance. The electrical characterization of two conductive poly-lactic acid (PLA) filaments, namely, c-PLA with carbon black and graphene PLA was performed to study the temperature coefficient of the resistance. Resistivity of carbon black filament was compared to a printed single layer and with that of a cube. The raw and printed c-PLA showed a positive temperature coefficient of resistance (α) ranging from ~0.03-0.01 ℃-1 while its counterpart in the study, graphene PLA, did not exhibit significant (α). Parts from graphene PLA with multilayer MEAM exhibited a negative α to a certain temperature before exhibiting positive α. The resistivity of the printed parts was 300 times higher for c-PLA and 1500 times for graphene PLA. However, no microstructural or chemical compositional changes were observed between the raw filaments and the printed parts. Due to the high α of the c-PLA, it was deemed as the better material for constructing electro thermal sensors and actuators using MEAM. First, c-PLA was used to fabricate and package a completely 3D printed flow meter that operates on the principle of Joule heating and hotwire anemometry. When the designed flowmeter was simulated using a finite element package, a flow sensitivity of -2.33 Ω sccm-1 and a relative change in resistivity of 0.036 sccm-1 was expected. For an operating voltage of 12-15 V, the experimental results showed a flow sensitivity within the range of 0.014-0.032 sccm-1 and the relative change in resistivity ranged from 0.039 – 0.065 sccm-1. Thus, a completely 3D printed flowmeter was demonstrated. Second, using the same principle of Joule heating, an actuator inspired from MEMS chevron grippers was designed, simulated, and fabricated. Simulation showed the feasibility of the structure and further predicted a displacement of a few hundred microns with a potential as low as 3 V with a cooling time as little less than 120 seconds. Experimentally, a displacement of 120.04, 97.05, and 88.96 μm were achieved in 15, 10, and 5 seconds with actuation potentials of 12.7, 13.8, and 17.9 V, respectively. As predicted by the simulation results, it took longer for the gripper to cool (close to 180 seconds) when compared to actuation times. During the above studies, we discovered the printing parameters altered the part resistance. Our final study examined how extrusion temperature and printing speed affects the impedance of the MEAM printed parts. Further, anisotropy in the impedance was observed and the influence of the interface to it was examined. From the experimental results, the anisotropy was quantified with a Z/F ratio and was found to be nearly constant, ~2.15±0.23. Impedance scaling with the number of interfaces was measured and showed conclusively that the interlayer bonding was the sole source for the observed Z/F ratio. Scanning electron microscope images shows the absence of air gaps at the interface, and energy dispersion spectroscopy shows the absence of oxidation at the interface. By investigating the role of print parameters and scaling of impedance with interfaces, a framework to model and predict electrical behavior of electro thermal sensors and actuators made via MEAM can be realized