Soft robot design methodology for ‘push-button’ manufacturing

‘Push-button’ or fully automated manufacturing would enable the production of robots with zero intervention from human hands. Realizing this utopia requires a fundamental shift from a sequential (design–materials–manufacturing) to a concurrent design methodology

Designing Origami-Adapted Deployable Modules for Soft Continuum Arms

© Springer Nature Switzerland AG 2019. Origami has several attractive attributes including deployability and portability which have been extensively adapted in designs of robotic devices. Drawing inspiration from foldable origami structures, this paper presents an engineering design process for fast making deployable modules of soft continuum arms. The process is illustrated with an example which adapts a modified accordion fold pattern to a lightweight deployable module. Kinematic models of the four-sided Accordion fold pattern is explored in terms of mechanism theory. Taking account of both the kinematic model and the materials selection, a 2D flat sheet model of the four-sided Accordion fold pattern is obtained for 3D printing. Following the design process, the deployable module is then fabricated by laminating 3D printed origami skeleton and flexible thermoplastic polyurethane (TPU) coated fabric. Preliminary tests of the prototype shown that the folding motion are enabled mainly by the flexible fabric between the gaps of thick panels of the origami skeleton and matches the kinematic analysis. The proposed approach has advantages of quick scaling dimensions, cost effective and fast fabricating thus allowing adaptive design according to specific demands of various tasks

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

Reconfigurable Surfaces Employing Linear-Rotational and Bistable-Translational (LRBT) Joints

Reconfigurable surfaces are useful in many applications. This paper proposes a type of reconfigurable surfaces that consist of rigid elements (tiles) connected by novel compliant joints. Depending on the actuation, these novel connecting joints can either operate as torsional hinges, which create isometric transformation (like origami folding) between connected tiles, or bistable translational springs, which accommodate metric-changing transformation between connected tiles. A specific example of a reconfigurable surface with square tile shape that can morph into flat, cylindrical (in two different directions), and spherical configurations with simple actuation is given

Reconfigurable Surfaces Employing Linear-Rotational and Bistable-Translational (LRBT) Joints

Reconfigurable surfaces are useful in many applications. This paper proposes a type of reconfigurable surfaces that consist of rigid elements (tiles) connected by novel compliant joints. Depending on the actuation, these novel connecting joints can either operate as torsional hinges, which create isometric transformation (like origami folding) between connected tiles, or bistable translational springs, which accommodate metric-changing transformation between connected tiles. A specific example of a reconfigurable surface with square tile shape that can morph into flat, cylindrical (in two different directions), and spherical configurations with simple actuation is given

Utilizing Systematic Design and Shape Memory Alloys to Enhance Actuation of Modular High-Frequency Origami Robots

Shape memory alloys (SMAs) describe a group of smart metallic materials that can be deformed by external magnetic, thermal, or mechanical influence and then returned to a predetermined shape through the cycling of temperature or stress. They have several advantages, such as having excellent mechanical properties, being low cost, and being easily manufactured, while also providing a compact size, completely silent operation, high work density, and requiring less maintenance over time. SMAs can undergo sold-to-solid phase transformations, and it is because of these phase transformations that they can experience shape memory effect (SME); or the ability to recover from a deformed shape to an initially determined shape through the cycling of temperature. However, since SME requires the cycling of temperature to actuate SMAs, the actuation frequency of these materials has been slow for small-scale applications, as actuation speed is limited by the time it takes to transition from a higher temperature (actuated, pre-determined state) to a lower temperature (flexible, reconfigurable state). While SMAs are known to be highly advantageous, their main drawback is that they are one of the slowest actuation methods in the field of origami robotics. SMAs cannot actuate quickly enough cyclically due to the long cooling times required to get from their austenite (higher temperature, actuated, pre-determined state) phase to their martensite (lower temperature, flexible, reconfigurable state) phase. Researchers have attempted to achieve a higher actuation speed in previous projects by using active cooling agents. However, this study investigated the use of SMAs to initiate high-frequency cyclic movement through a small-scale origami fold without an active cooling source. This study used a combination of different system design parameters to mechanically hasten the actuation speed of a folding hinge with no cooling component present. Through only design and a complete understanding of the SMAs, this study achieved consistent and relatively high results (\u3e1.5 Hz) of an actuation speed for a system of this size. This study discovered knowledge regarding the composition, material properties, and actuation limits of SMAs, and a new systematic design method was proposed for creating origami robots

A Review of SMA-Based Actuators for Bidirectional Rotational Motion: Application to Origami Robots

Shape memory alloys (SMAs) are a group of metallic alloys capable of sustaining large inelastic strains that can be recovered when subjected to a specific process between two distinct phases. Regarding their unique and outstanding properties, SMAs have drawn considerable attention in various domains and recently became appropriate candidates for origami robots, that require bi-directional rotational motion actuation with limited operational space. However, longitudinal motion-driven actuators are frequently investigated and commonly mentioned, whereas studies in SMA-based rotational motion actuation is still very limited in the literature. This work provides a review of different research efforts related to SMA-based actuators for bi-directional rotational motion (BRM), thus provides a survey and classification of current approaches and design tools that can be applied to origami robots in order to achieve shape-changing. For this purpose, analytical tools for description of actuator behaviour are presented, followed by characterisation and performance prediction. Afterward, the actuators’ design methods, sensing, and controlling strategies are discussed. Finally, open challenges are discussed

Development of a Fabrication Technique for Soft Planar Inflatable Composites

Soft robotics is a rapidly growing field in robotics that combines aspects of biologically inspired characteristics to unorthodox methods capable of conforming and/or adapting to unknown tasks or environments that would otherwise be improbable or complex with conventional robotic technologies. The field of soft robotics has grown rapidly over the past decade with increasing popularity and relevance to real-world applications. However, the means of fabricating these soft, compliant and intricate robots still poses a fundamental challenge, due to the liberal use of soft materials that are difficult to manipulate in their original state such as elastomers and fabric. These material properties rely on informal design approaches and bespoke fabrication methods to build soft systems. As such, there are a limited variety of fabrication techniques used to develop soft robots which hinders the scalability of robots and the time to manufacture, thus limiting their development. This research focuses towards developing a novel fabrication method for constructing soft planar inflatable composites. The fundamental method is based on a sub-set of additive manufacturing known as composite layering. The approach is designed from a planar manner and takes layers of elastomeric materials, embedded strain-limiting and mask layers. These components are then built up through a layer-by-layer fabrication method with the use of a bespoke film applicator set-up. This enables the fabrication of millimetre-scale soft inflatable composites with complex integrated masks and/or strain-limiting layers. These inflatable composites can then be cut into a desired shape via laser cutting or ablation. A design approach was also developed to expand the functionality of these inflatable composites through modelling and simulation via finite element analysis. Proof of concept prototypes were designed and fabricated to enable pneumatic driven actuation in the form of bending soft actuators, adjustable stiffness sensor, and planar shape change. This technique highlights the feasibility of the fabrication method and the value of its use in creating multi-material composite soft actuators which are thin, compact, flexible, and stretchable and can be applicable towards real-world application