Evaluation of 3D Printed Soft Robots in Radiation Environments and Comparison With Molded Counterparts

Robots have an important role during inspection, clean-up, and sample collection in unstructured radiation environments inaccessible to humans. The advantages of soft robots, such as body morphing, high compliance, and energy absorption during impact, make them suitable for operating under extreme conditions. Despite their promise, the usefulness of soft robots under a radiation environment has yet to be assessed. In this work, we evaluate the effectiveness of soft robots fabricated from polydimethylsiloxane (PDMS), a common fabrication material, under radiation for the first time. We investigated gamma-induced mechanical damage in the PDMS materials' mechanical properties, including elongation, tensile strength, and stiffness. We selected three radiation environments from the nuclear industry to represent a wide range of radiation and then submerged a 3D printed hexapus robot into a radiation environment to estimate its operation time. Finally, to test the reliability of the 3D printed soft robots, we compared their performances with molded counterparts. To analyze performance results in detail, we also investigated dimensional errors and the effects of fabrication methods, nozzle size, and print direction on the stiffness of PDMS material. Results of this study show that with increasing exposure to gamma irradiation, the mechanical properties of PDMS decrease in functionality but are minimally impacted up to 20 kGy gamma radiation. Considering the fractional changes to the PDMS mechanical properties, it is safe to assume that soft robots could operate for 12 h in two of the three proposed radiation environments. We also verified that the 3D printed soft robots can perform better than or equal to their molded counterparts while being more reliable

An agile multi-body additively manufactured soft actuator for soft manipulators

With the introduction of collaborative robots in production environments, the harm to workers by using traditional robots with rigid links is inherent. A new generation of robots made from flexible soft materials that decreases collision danger by self-deforming actions has been proposed as a promising solution for the human-robot collaboration environments. Recently, by the development of additive manufacture of elastic soft materials, new design opportunities arise for these so-called soft robots. However, robustness that is required for production environments is still not achieved. This paper presents a design approach of a fully additively manufactured three-axis soft pneumatic actuator. For its use in flexible soft robotic manipulator systems, design guidelines, a direct 3D printing process with elastic materials and a low-level PLC semi-automated pressure regulation control system are presented. To validate the proposed design, the actuator is manufactured and tested for maximum contact force, bending motion reaction and its signal response.Con la introducción de robots colaborativos en entornos de producción, el daño a los trabajadores por el uso de robots tradicionales con enlaces rígidos es inherente. Se ha propuesto una nueva generación de robots hechos de materiales blandos flexibles que reduce el peligro de colisión mediante acciones de autodeformación como una solución prometedora para los entornos de colaboración humano-robot. Recientemente, con el desarrollo de la fabricación aditiva de materiales blandos elásticos, surgen nuevas oportunidades de diseño para estos llamados robots blandos. Sin embargo, aún no se logra la robustez que se requiere para los entornos de producción. Este documento presenta un enfoque de diseño de un actuador neumático blando de tres ejes fabricado de forma totalmente aditiva. Para su uso en sistemas de manipuladores robóticos blandos flexibles, se presentan pautas de diseño, un proceso de impresión 3D directo con materiales elásticos y un sistema de control de regulación de presión semiautomatizado PLC de bajo nivel. Para validar el diseño propuesto, el actuador se fabrica y prueba para la fuerza de contacto máxima, la reacción de movimiento de flexión y su respuesta de señal

Conventional and Additively Manufactured Stainless Steels: A Review

© The Indian Institute of Metals - IIM 2021. This is the accepted manuscript version of an article which has been published in final form at https://doi.org/10.1007/s12666-021-02305-7For the last three decades, enormous manufacturing processes have been widely employed in the field of transportation (aviation, automobile and marine) as well as various industrial sectors. Among the invented techniques, conventional manufacturing plays a versatile and cost effective role, but additive manufacturing (AM) possesses a more significant advantage of handling complicated parts or complex geometrical structures. The conventional processes were used from ancient times until the development of other advanced techniques. In recent development of technology, AM technology has shown a tremendous change in the manufacturing field. The process of development in AM began with polymers, then to composites and advanced to nanocomposites, continuously. AM provides a waste-free production management system with enhanced processes. Therefore, this detailed and compendious review describes the different stainless steels fabricated through conventional and AM techniques. It is evident that AM proves better than other several conventional techniques, by three dimensional (3D) printing of quality and complex stainless steels components that are impossible to manufacture through other methods. Notwithstanding, there still need of much efforts to improve AM technique by reducing the manufacturing cost, supporting mass production and printing large stainless steel components. With an increase in invention of various efficient state-of-the-art engineering software, robots in manufacturing, artificial intelligence and smart manufacturing, the aforementioned drawbacks of AM technique/3D printing of various stainless steel structures will be soon eradicated.Peer reviewe

Soft pneumatic actuators: a review of design, fabrication, modeling, sensing, control and applications

Soft robotics is a rapidly evolving field where robots are fabricated using highly deformable materials and usually follow a bioinspired design. Their high dexterity and safety make them ideal for applications such as gripping, locomotion, and biomedical devices, where the environment is highly dynamic and sensitive to physical interaction. Pneumatic actuation remains the dominant technology in soft robotics due to its low cost and mass, fast response time, and easy implementation. Given the significant number of publications in soft robotics over recent years, newcomers and even established researchers may have difficulty assessing the state of the art. To address this issue, this article summarizes the development of soft pneumatic actuators and robots up until the date of publication. The scope of this article includes the design, modeling, fabrication, actuation, characterization, sensing, control, and applications of soft robotic devices. In addition to a historical overview, there is a special emphasis on recent advances such as novel designs, differential simulators, analytical and numerical modeling methods, topology optimization, data-driven modeling and control methods, hardware control boards, and nonlinear estimation and control techniques. Finally, the capabilities and limitations of soft pneumatic actuators and robots are discussed and directions for future research are identified

Fused Filament Fabrication of Prosthetic Components for Trans-Humeral Upper Limb Prosthetics

abstract: Presented below is the design and fabrication of prosthetic components consisting of an attachment, tactile sensing, and actuator systems with Fused Filament Fabrication (FFF) technique. The attachment system is a thermoplastic osseointegrated upper limb prosthesis for average adult trans-humeral amputation with mechanical properties greater than upper limb skeletal bone. The prosthetic designed has: a one-step surgical process, large cavities for bone tissue ingrowth, uses a material that has an elastic modulus less than skeletal bone, and can be fabricated on one system. FFF osseointegration screw is an improvement upon the current two-part osseointegrated prosthetics that are composed of a fixture and abutment. The current prosthetic design requires two invasive surgeries for implantation and are made of titanium, which has an elastic modulus greater than bone. An elastic modulus greater than bone causes stress shielding and overtime can cause loosening of the prosthetic. The tactile sensor is a thermoplastic piezo-resistive sensor for daily activities for a prosthetic’s feedback system. The tactile sensor is manufactured from a low elastic modulus composite comprising of a compressible thermoplastic elastomer and conductive carbon. Carbon is in graphite form and added in high filler ratios. The printed sensors were compared to sensors that were fabricated in a gravity mold to highlight the difference in FFF sensors to molded sensors. The 3D printed tactile sensor has a thickness and feel similar to human skin, has a simple fabrication technique, can detect forces needed for daily activities, and can be manufactured in to user specific geometries. Lastly, a biomimicking skeletal muscle actuator for prosthetics was developed. The actuator developed is manufactured with Fuse Filament Fabrication using a shape memory polymer composite that has non-linear contractile and passive forces, contractile forces and strains comparable to mammalian skeletal muscle, reaction time under one second, low operating temperature, and has a low mass, volume, and material costs. The actuator improves upon current prosthetic actuators that provide rigid, linear force with high weight, cost, and noise.Dissertation/ThesisDoctoral Dissertation Biomedical Engineering 201

Functional Materials and Techniques for Additive Manufacturing in Soft Robotics

This thesis outlines the development of new elastomeric materials and manufacturing processes for soft robotics. Specifically, this work describes the development of custom material formulations for use in additive manufacturing, additive manufacturing processing techniques for silicone elastomers, and multi-component additive manufacturing techniques. Material synthesis and processing is a gap in the field that needs more research to produce more predictable, higher quality, and more scalable soft robot technologies. This thesis includes papers that address the above topics, preceded by an introduction and literature review into additive manufacturing and materials characterization for soft robotics. The first work (Chapter 2) outlines the development of a custom elastomer designed to make biodegradable soft robots via 3D printing. The second work (Chapter 3) shows how liquid silicone thermoset polymers 3d printing can be improved by controlling reaction kinetics and rheology. The last work (Chapter 4) describes the process of using silicone 3D printing to embed multiple discrete sensing and electronic components into a functioning soft wearable device, with a focus on customizability. Each work describes a different part of how materials science plays a role in soft robotics, including the creation of elastomeric material, control of the elastomeric material, and combining the multiple materials in custom device manufacturing. For each work, a soft robot actuator or robot system is developed to emphasize the importance of material behavior and process development in improving soft robot manufacturing

A Holistic Approach to Human-Supervised Humanoid Robot Operations in Extreme Environments

Nuclear energy will play a critical role in meeting clean energy targets worldwide. However, nuclear environments are dangerous for humans to operate in due to the presence of highly radioactive materials. Robots can help address this issue by allowing remote access to nuclear and other highly hazardous facilities under human supervision to perform inspection and maintenance tasks during normal operations, help with clean-up missions, and aid in decommissioning. This paper presents our research to help realize humanoid robots in supervisory roles in nuclear environments. Our research focuses on National Aeronautics and Space Administration (NASA’s) humanoid robot, Valkyrie, in the areas of constrained manipulation and motion planning, increasing stability using support contact, dynamic non-prehensile manipulation, locomotion on deformable terrains, and human-in-the-loop control interfaces

A Digital Manufacturing Process For Three-Dimensional Electronics

Additive manufacturing (AM) offers the ability to produce devices with a degree of three-dimensional complexity and mass customisation previously unachievable with subtractive and formative approaches. These benefits have not transitioned into the production of commercial electronics that still rely on planar, template-driven manufacturing, which prevents them from being tailored to the end user or exploiting conformal circuitry for miniaturisation. Research into the AM fabrication of 3D electronics has been demonstrated; however, because of material restrictions, the durability and electrical conductivity of such devices was often limited. This thesis presents a novel manufacturing approach that hybridises the AM of polyetherimide (PEI) with chemical modification and selective light-based synthesis of silver nanoparticles to produce 3D electronic systems. The resulting nanoparticles act as a seed site for the electroless deposition of copper. The use of high-performance materials for both the conductive and dielectric elements created devices with the performance required for real-world applications. For printing PEI, a low-cost fused filament fabrication (FFF); also known as fused deposition modelling (FDM), printer with a unique inverted design was developed. The orientation of the printer traps hot air within a heated build environment that is open on its underside allowing the print head to deposit the polymer while keeping the sensitive components outside. The maximum achievable temperature was 120 °C and was found to reduce the degree of warping and the ultimate tensile strength of printed parts. The dimensional accuracy was, on average, within 0.05 mm of a benchmark printer and fine control over the layer thickness led to the discovery of flexible substrates that can be directly integrated into rigid parts. Chemical modification of the printed PEI was used to embed ionic silver into the polymer chain, sensitising it to patterning with a 405 nm laser. The rig used for patterning was a re-purposed vat-photopolymerisation printer that uses a galvanometer to guide the beam that is focused to a spot size of 155 µm at the focal plane. The positioning of the laser spot was controlled with an open-sourced version of the printers slicing software. The optimal laser patterning parameters were experimentally validated and a link between area-related energy density and the quality of the copper deposition was found. In tests where samples were exposed to more than 2.55 J/cm^2, degradation of the polymer was experienced which produced blistering and delamination of the copper. Less than 2.34 J/cm^2 also had negative effect and resulted in incomplete coverage of the patterned area. The minimum feature resolution produced by the patterning setup was 301 µm; however, tests with a photomask demonstrated features an order of magnitude smaller. The non-contact approach was also used to produce conformal patterns over sloped and curved surfaces. Characterisation of the copper deposits found an average thickness of 559 nm and a conductivity of 3.81 × 107 S/m. Tape peel and bend fatigue testing showed that the copper was ductile and adhered well to the PEI, with flexible electronic samples demonstrating over 50,000 cycles at a minimum bend radius of 6.59 mm without failure. Additionally, the PEI and copper combination was shown to survive a solder reflow with peak temperatures of 249°C. Using a robotic pick and place system a test board was automatically populated with surface mount components as small as 0201 resistors which were affixed using high-temperature, Type-V Tin-Silver-Copper solder paste. Finally, to prove the process a range of functional demonstrators were built and evaluated. These included a functional timer circuit, inductive wireless power coils compatible with two existing standards, a cylindrical RF antenna capable of operating at several frequencies below 10 GHz, flexible positional sensors, and multi-mode shape memory alloy actuators