Enabling New Functionally Embedded Mechanical Systems Via Cutting, Folding, and 3D Printing

Traditional design tools and fabrication methods implicitly prevent mechanical engineers from encapsulating full functionalities such as mobility, transformation, sensing and actuation in the early design concept prototyping stage. Therefore, designers are forced to design, fabricate and assemble individual parts similar to conventional manufacturing, and iteratively create additional functionalities. This results in relatively high design iteration times and complex assembly strategies

Challenges and Status on Design and Computation for Emerging Additive Manufacturing Technologies

The revolution of additive manufacturing (AM) has led to many opportunities in fabricating complex and novel products. The increase of printable materials and the emergence of novel fabrication processes continuously expand the possibility of engineering systems in which product components are no longer limited to be single material, single scale, or single function. In fact, a paradigm shift is taking place in industry from geometry-centered usage to supporting functional demands. Consequently, engineers are expected to resolve a wide range of complex and difficult problems related to functional design. Although a higher degree of design freedom beyond geometry has been enabled by AM, there are only very few computational design approaches in this new AM-enabled domain to design objects with tailored properties and functions. The objectives of this review paper are to provide an overview of recent additive manufacturing developments and current computer-aided design methodologies that can be applied to multimaterial, multiscale, multiform, and multifunctional AM technologies. The difficulties encountered in the computational design approaches are summarized and the future development needs are emphasized. In the paper, some present applications and future trends related to additive manufacturing technologies are also discussed

Kinegami: Algorithmic Design of Compliant Kinematic Chains From Tubular Origami

Origami processes can generate both rigid and compliant structures from the same homogeneous sheet material. In this article, we advance the origami robotics literature by showing that it is possible to construct an arbitrary rigid kinematic chain with prescribed joint compliance from a single tubular sheet. Our “Kinegami” algorithm converts a Denavit–Hartenberg specification into a single-sheet crease pattern for an equivalent serial robot mechanism by composing origami modules from a catalogue. The algorithm arises from the key observation that tubular origami linkage design reduces to a Dubins path planning problem. The automatically generated structural connections and movable joints that realize the specified design can also be endowed with independent user-specified compliance. We apply the Kinegami algorithm to a number of common robot mechanisms and hand-fold their algorithmically generated single-sheet crease patterns into functioning kinematic chains. We believe this is the first completely automated end-to-end system for converting an abstract manipulator specification into a physically realizable origami design that requires no additional human input

Mechanics Modeling of Non-rigid Origami: From Qualitative to Quantitative Accuracy

Origami, the ancient art of paper folding, has recently evolved into a design and fabrication framework for various engineering systems at vastly different scales: from large-scale deployable airframes to mesoscale biomedical devices to small-scale DNA machines. The increasingly diverse applications of origami require a better understanding of the fundamental mechanics and dynamics induced by folding. Therefore, formulating a high-fidelity simulation model for origami is crucial, especially when large amplitude deformation/rotation exists during folding. The currently available origami simulation models can be categorized into three branches: rigid-facet models, bar-hinge models, and finite element models. The first branch of models assumes that the origami facets are rigid panels and creases behaving like hinges. It is a powerful tool for kinematics analysis without unnecessary complexities. On the other hand, the bar-hinge models have become widely used for simulating nonrigid-foldable origamis. The basic idea of these models is to place stretchable bar elements along the creases and across facet diagonals, discretizing the continuous origami into a pin-jointed truss frame system. Therefore, one can analyze facet deformations, including in-plane shearing, out-of-plane bending, and twisting. Moreover, more complex crease deformations can also be captured by adding appropriate components to the bar-hinge models. Because of their simplicity and modeling capability, the bar-hinge models have been utilized with many successes in analyzing the global deformation of non-rigid origami and uncovering its mechanical principles. However, one can only achieve qualitatively accurate predictions of the bar-hinge models compared to the physical experiments, especially when complex deformation exists during origami folding. The third branch, finite element models, does not impose explicit simplification on the facet deformation using shell elements. It can accurately analyze the deformation modes of origami structures; however, their disadvantages are also evident. On the one hand, it requires a time-consuming cycle for both modeling and computing, including pre-processing and post-processing. On the other hand, the traditional shell element might experience convergence issues when large and dynamic rotations occur, as commonly observed in origami systems. This thesis investigates the mechanics modeling of non-rigid origami and proposes a new dynamic model based on Absolute Nodal Coordinate Formulation (ANCF hereafter). Firstly, we discuss the accuracy of the widely used bar-hinge model through a case study on the multi-stability behavior in a non-rigid stacked Miura-origami structure. The model successfully investigates the underpinning principles of the multi-stability behavior in non-rigid origami and finds the existence of asymmetric energy barriers for extension and compression by tailoring its crease stiffness and facet bending stiffness. This interesting phenomenon can be exploited to create a mechanical diode. Experiment results confirm the existence of asymmetric multi-stability; however, the model\u27s prediction is only qualitatively verified due to its assumption of discrete lattices. In the next part, we develop a new origami mechanics model based on ANCF, a powerful modeling tool for the nonlinear dynamic simulation of multibody systems with large rotation and deformation. The new model treats origami as ANCF thin plate elements rotating around compliant creases, and the so-called torsional spring damper connectors are developed and utilized to simulate crease folding. Finally, its modeling accuracy is experimentally validated through two case studies, including motion analysis of simple fold mechanism and dynamic deployment of Miura-ori structures. The new origami simulation model can be used to quantitatively predict the dynamic responses of non-rigid origami with complex deformations. It can help deepen our knowledge of folding-induced mechanics and dynamics and broaden the application of origami in science and engineering

A Certified-Complete Bimanual Manipulation Planner

Planning motions for two robot arms to move an object collaboratively is a difficult problem, mainly because of the closed-chain constraint, which arises whenever two robot hands simultaneously grasp a single rigid object. In this paper, we propose a manipulation planning algorithm to bring an object from an initial stable placement (position and orientation of the object on the support surface) towards a goal stable placement. The key specificity of our algorithm is that it is certified-complete: for a given object and a given environment, we provide a certificate that the algorithm will find a solution to any bimanual manipulation query in that environment whenever one exists. Moreover, the certificate is constructive: at run-time, it can be used to quickly find a solution to a given query. The algorithm is tested in software and hardware on a number of large pieces of furniture.Comment: 12 pages, 7 figures, 1 tabl

Functional Soft Robotic Actuators Based on Dielectric Elastomers

Dielectric elastomer actuators (DEAs) are a promising soft actuator technology for robotics. Adding robotic functionalities--folding, variable stiffness, and adhesion--into their actuator design is a novel method to create functionalized robots with simplified actuator configurations. We first propose a foldable actuator that has a simple antagonistic DEA configuration allowing bidirectional actuation and passive folding. To prove the concept, a foldable elevon actuator with outline size of 70 mm × 130 mm is developed with a performance specification matched to a 400 mm wingspan micro air vehicle (MAV) of mass 130 g. The developed actuator exhibits actuation angles up to ± 26 ° and a torque of 2720 mN·mm in good agreement with a prediction model. During a flight, two of these integrated elevon actuators well controlled the MAV, as proven by a strong correlation of 0.7 between the control signal and the MAV motion. We next propose a variable stiffness actuator consisting of a pre-stretched DEA bonded on a low-melting-point alloy (LMPA) embedded silicone substrate. The phase of the LMPA changes between liquid and solid enabling variable stiffness of the structure, between soft and rigid states, while the DEA generates a bending actuation. A proof-of-concept actuator with dimension 40 mm length × 10mm width × 1mm thickness and a mass of 1 g is fabricated and characterized. Actuation is observed up to 47.5 ° angle and yielding up to 2.4 mN of force in the soft state. The stiffness in the rigid state is ~90 × larger than an actuator without LMPA. We develop a two-finger gripper in which the actuators act as the fingers. The rigid state allows picking up an object mass of 11 g (108 mN), to be picked up even though the actuated grasping force is only 2.4 mN. We finally propose an electroadhesion actuator that has a DEA design simultaneously maximizing electroadhesion and electrostatic actuation, while allowing self-sensing by employing an interdigitated electrode geometry. The concept is validated through development of a two-finger soft gripper, and experimental samples are characterized to address an optimal design. We observe that the proposed DEA design generates 10 × larger electroadhesion force compared to a conventional DEA design, equating to a gripper with a high holding force (3.5 N shear force for 1 cm^2) yet a low grasping force (1 mN). These features make the developed simple gripper to handle a wide range of challenging objects such as highly-deformable water balloons (35.6 g), flat paper (0.8 g), and a raw chicken egg (60.9 g), with its lightweight (1.5 g) and fast movement (100 ms to close fingers). The results in this thesis address the creation of the functionalized robots and expanding the use of DEAs in robotics

Double‐spirals offer the development of pre‐programmable modular metastructures

Metamaterials with adjustable, sometimes unusual properties offer advantages over conventional materials with predefined mechanical properties in many technological applications. A group of metamaterials, called modular metamaterials or metastructures, are developed through the arrangement of multiple, mostly similar building blocks. These modular structures can be assembled using prefabricated modules and reconfigured to promote efficiency and functionality. Here, we developed a novel modular metastructure by taking advantage of the high compliance of pre-programmable double-spirals. First, we simulated the mechanical behavior of a four-module metastructure under tension, compression, rotation, and sliding using the finite-element method. Then, we used 3D printing and mechanical testing to illustrate the tunable anisotropic and asymmetric behavior of spiral-based metastructures in practice. Our results show the simple reconfiguration of the presented metastructure toward the desired functions. The mechanical behavior of single double-spirals and the characteristics that can be achieved through their combinations make our modular metastructure suitable for various applications in robotics, aerospace, and medical engineering