Design, Modeling and Control of a 3D Printed Monolithic Soft Robotic Finger with Embedded Pneumatic Sensing Chambers

IEEE This paper presents a directly 3D printed soft monolithic robotic finger with embedded soft pneumatic sensing chambers (PSC) as position and touch sensors. The monolithic finger was fabricated using a low-cost and open-source fused deposition modeling (FDM) 3D printer that employs an off-the-shelf soft and flexible commercially available thermoplastic polyurethane (TPU). A single soft hinge with an embedded PSC was optimized using finite element modeling (FEM) and a hyperelastic material model to obtain a linear relationship between the internal change in the volume of its PSC and the corresponding input mechanical modality, to minimize its bending stiffness and to maximize its internal volume. The soft hinges with embedded PSCs have several advantages, such as fast response to very small changes in their internal volume (~0.0026ml/°), linearity, negligible hysteresis, repeatability, reliability, long lifetime and low power consumption. Also, the flexion of the soft robotic finger was predicted using a geometric model for use in real-time control. The real-time position and pressure/force control of the soft robotic finger were achieved using feedback signals from the soft hinges and the touch PSC embedded in the tip of the finger. This study contributes to the development of seamlessly embedding optimized sensing elements in the monolithic topology of a soft robotic system and controlling the robotic system using the feedback data provided by the sensing elements to validate their performance

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

A 3D-Printed Omni-Purpose Soft Gripper

Numerous soft grippers have been developed based on smart materials, pneumatic soft actuators, and underactuated compliant structures. In this article, we present a three-dimensional (3-D) printed omni-purpose soft gripper (OPSOG) that can grasp a wide variety of objects with different weights, sizes, shapes, textures, and stiffnesses. The soft gripper has a unique design that incorporates soft fingers and a suction cup that operate either separately or simultaneously to grasp specific objects. A bundle of 3-D-printable linear soft vacuum actuators (LSOVA) that generate a linear stroke upon activation is employed to drive the tendon-driven soft fingers. The support, fingers, suction cup, and actuation unit of the gripper were printed using a low-cost and open-source fused deposition modeling 3-D printer. A single LSOVA has a blocked force of 30.35 N, a rise time of 94 ms, a bandwidth of 2.81 Hz, and a lifetime of 26 120 cycles. The blocked force and stroke of the actuators are accurately predicted using finite element and analytical models. The OPSOG can grasp at least 20 different objects. The gripper has a maximum payload-to-weight ratio of 7.06, a grip force of 31.31 N, and a tip blocked force of 3.72 N

3D PRINTING OF IRON OXIDE INCORPORATED POLYDIMETHYLSILOXANE SOFT MAGNETIC ACTUATOR

Soft actuators have grown to be a topic of great scientific interest recently. As the fabrication of soft actuators with conventional microfabrication methods are tedious, expensive, and time consuming, employment of 3-D printing fabrication methods appears promising as they can simplify fabrication and reduce the production cost. Complex structures can be fabricated with 3-D printing such as helical coils can achieve actuation performances that otherwise would not be possible with simpler geometries. In this thesis development of soft magnetic helical coil actuators of iron-oxide embedded polydimethylsiloxane (PDMS) was achieved with embedded 3-D printing techniques. Composites with three different weight ratios of 10%, 20%, and 30% iron nanoparticles to PDMS were formulated. Using iron nanoparticles with 15-20nm size helps preserve viscosity of the printing material low enough that it was possible to print it with small gauge 29 needle (180 micrometers inner diameter). The hydrogel support of Pluroic f-127 bath and the ability to maintain the ratio of the printed fiber’s diameter to coil diameter close to 0.25 approximately resulted in the successful fabrication and release of fabricated helical coil structures. This enabled 3-D printed structures characterized as magnetic actuators to achieve linear and bending actuation of more than 300% and 80°respectively in the case of composites with 30% iron oxide nanoparticles. Moreover, it was shown that the 3D printed helical coils with 10% iron oxide nanoparticles can be utilized as an untethered soft robot that is capable of locomotion on 45 and 90 degrees inclines under an applied magnetic field

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

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

4D Printing Dielectric Elastomer Actuator Based Soft Robots

4D printing is an emerging technology that prints 3D structural smart materials that can respond to external stimuli and change shape over time. 4D printing represents a major manufacturing paradigm shift from single-function static structures to dynamic structures with highly integrated functionalities. Direct printing of dynamic structures can provide great benefits (e.g., design freedom, low material cost) to a wide variety of applications, such as sensors and actuators, and robotics. Soft robotics is a new direction of robotics in which hard and rigid components are replaced by soft and flexible materials to mimic mechanisms that works in living creatures, which are crucial for dealing with uncertain and dynamic tasks. However, little research on direct printing of soft robotics has been reported. Due to the short history of 4D printing, only a few smart materials have been successfully 4D printed, such as shape memory and thermo-responsive polymers, which have relatively small actuation strains (up to ~8%). In order to produce the large motion, dielectric elastomer actuator (DEA), a sheet of elastomer sandwiched between two compliant electrodes and known as artificial muscle for its high elastic energy density and capability of producing large strains (~200%), is chosen as the actuator for soft robotics. Little research on 3D printing silicone DEA soft robotics has been done in the literature. Thus, this thesis is motivated by applying the advantages in 3D printing fabrication methods to develop DEA soft robotics. The ultimate research goal is to demonstrate fully printed DEA soft robots with large actuation. In Chapter 1, the research background of soft robotics and DEAs are introduced, as well as 3D printing technologies. Chapter 2 reports the rules of selecting potentially good silicone candidates and the printing process with printed material characterizations. Chapter 3 studies the effects of pre-strain condition on silicone material properties and the performance of DEA configurations, in order to obtain large actuation strain. In Chapter 4, two facial soft robots are designed to achieve facial expressions as judged by a smiling lip and expanding pupils based on DEA actuation. Conclusions and future developments are given in chapter 5 and 6, respectively

Bio-Inspired Active Skins for Surface Morphing.

Mechanical metamaterials that leverage precise geometrical designs and imperfections to induce unique material behavior have garnered significant attention. This study proposes a Bio-Inspired Active Skin (BIAS) as a new class of instability-induced morphable structures, where selective out-of-plane material deformations can be pre-programmed during design and activated by in-plane strains. The deformation mechanism of a unit cell geometrical design is analyzed to identify how the introduction of hinge-like notches or instabilities, versus their pristine counterparts, can pave way for controlling bulk BIAS behavior. Two-dimensional arrays of repeating unit cells were fabricated, with notches implemented at key locations throughout the structure, to harvest the instability-induced surface features for applications such as camouflage, surface morphing, and soft robotic grippers