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

Modular soft pneumatic actuator system design for compliance matching

The future of robotics is personal. Never before has technology been as pervasive as it is today, with advanced mobile electronics hardware and multi-level network connectivity pushing âsmartâ devices deeper into our daily lives through home automation systems, virtual assistants, and wearable activity monitoring. As the suite of personal technology around us continues to grow in this way, augmenting and offloading the burden of routine activities of daily living, the notion that this trend will extend to robotics seems inevitable. Transitioning robots from their current principal domain of industrial factory settings to domestic, workplace, or public environments is not simply a matter of relocation or reprogramming, however. The key differences between âtraditionalâ types of robots and those which would best serve personal, proximal, human interactive applications demand a new approach to their design. Chief among these are requirements for safety, adaptability, reliability, reconfigurability, and to a more practical extent, usability. These properties frame the context and objectives of my thesis work, which seeks to provide solutions and answers to not only how these features might be achieved in personal robotic systems, but as well what benefits they can afford. I approach the investigation of these questions from a perspective of compliance matching of hardware systems to their applications, by providing methods to achieve mechanical attributes complimentary to their environment and end-use. These features are fundamental to the burgeoning field of Soft Robotics, wherein flexible, compliant materials are used as the basis for the structure, actuation, sensing, and control of complete robotic systems. Combined with pressurized air as a power source, soft pneumatic actuator (SPA) based systems offers new and novel methods of exploiting the intrinsic compliance of soft material components in robotic systems. While this strategy seems to answer many of the needs for human-safe robotic applications, it also brings new questions and challenges: What are the needs and applications personal robots may best serve? Are soft pneumatic actuators capable of these tasks, or âusefulâ work output and performance? How can SPA based systems be applied to provide complex functionality needed for operation in diverse, real-world environments? What are the theoretical and practical challenges in implementing scalable, multiple degrees of freedom systems, and how can they be overcome? I present solutions to these problems in my thesis work, elucidated through scientific design, testing and evaluation of robotic prototypes which leverage and demonstrate three key features: 1) Intrinsic compliance: provided by passive elastic and flexible component material properties, 2) Extrinsic compliance: rendered through high number of independent, controllable degrees of freedom, and 3) Complementary design: exhibited by modular, plug and play architectures which combine both attributes to achieve compliant systems. Through these core projects and others listed below I have been engaged in soft robotic technology, its application, and solutions to the challenges which are critical to providing a path forward within the soft robotics field, as well as for the future of personal robotics as a whole toward creating a better society

Fabrication of Microfluidic Devices for Emulsion Formation by Microstereolithography

Droplet microfluidics—the art and science of forming droplets—has been revolutionary for high-throughput screening, directed evolution, single-cell sequencing, and material design. However, traditional fabrication techniques for microfluidic devices suffer from several disadvantages, including multistep processing, expensive facilities, and limited three-dimensional (3D) design flexibility. High-resolution additive manufacturing—and in particular, projection micro-stereolithography (PµSL)—provides a promising path for overcoming these drawbacks. Similar to polydimethylsiloxane-based microfluidics 20 years ago, 3D printing methods, such as PµSL, have provided a path toward a new era of microfluidic device design. PµSL greatly simplifies the device fabrication process, especially the access to truly 3D geometries, is cost-effective, and it enables multimaterial processing. In this review, we discuss both the basics and recent innovations in PµSL; the material basis with emphasis on custom-made photopolymer formulations; multimaterial 3D printing; and, 3D-printed microfluidic devices for emulsion formation as our focus application. Our goal is to support researchers in setting up their own PµSL system to fabricate tailor-made microfluidics

Distributed manufacturing with 3-D printing: a case study of recreational vehicle solar photovoltaic mounting systems

International audienceFor the first time, low-cost open-source 3-D printing provides the potential for distributed manufacturing at the household scale of customized, high-value, and complex products. To explore the potential of this type of ultra-distributed manufacturing, which has been shown to reduce environmental impact compared to conventional manufacturing, this paper presents a case study of a 3-D printable parametric design for recreational vehicle (RV) solar photovoltaic (PV) racking systems. The design is a four-corner mounting device with the ability to customize the tilt angle and height of the standoff. This enables performance optimization of the PV system for a given latitude, which is variable as RVs are geographically mobile. The open-source 3-D printable designs are fabricated and analyzed for print time, print electricity consumption, mechanical properties, and economic costs. The preliminary results show distributed manufacturing of the case study product results in an order of magnitude reduction in economic cost for equivalent products. In addition, these cost savings are maintained while improving the functionality of the racking system. The additional electrical output for a case study RV PV system with improved tilt angle functionality in three representative locations in the U.S. was found to be on average over 20% higher than that for conventional mass-manufactured racking systems. The preliminary results make it clear that distributed manufacturing-even at the household level-with open-source 3-D printers is technically viable and economically beneficial. Further research is needed to expand the results of this preliminary study to other types of products

Towards a methodology for integrated freeform manufacturing systems development with a control systems emphasis

A variety of fully integrated Freeform Fabrication (FFF) systems have been developed, a selected group for research and several for commercialization. The design methodology behind most of them is not documented, standardized, or rational. It is important to understand that the final product from any integrated system is affected not only by the unit manufacturing processes themselves, but also by the extent the individual units are assimilated into an integrated process. Thus, a scheme consisting of eight steps and the salient five elements necessary to create or retrofit an existing system to achieve an Integrated Freeform Manufacturing System (FFMS) is proposed in this thesis. Specifically, mass-change, deformation and consolidation unit manufacturing processes are emphasized, as the priority is focused on rapid prototyping (RP) technologies. To illustrate the proposed scheme, the University of Missouri-Rolla (UMR) Laser Aided Manufacturing Process (LAMP) system is presented --Abstract, page iv

Novel pneumatic circuit for the computational control of soft robots

Soft robots are of significant research interest in recent decades due to their adaptability to unstructured environments and safe interaction with humans. Soft pneumatic robots, one of the most dominant subsets of soft robots, utilize the interaction between soft elastomeric materials and pressurized air to achieve desired functions. However, the systems currently used for signal computation and pneumatic regulation often make use of rigid valves, pumps, syringe drivers, microcontrollers et al. These bulky and non-integrable devices limit the performance of pneumatically-driven soft robots, carrying challenges for the robot to be miniaturized, untethered, and agile. This DPhil aims to develop pneumatic circuits that can be integrated into the soft robot bodies while performing both onboard computation and control. This thesis presents our contributions towards the aforementioned objective step by step. Firstly, we designed a 3D-printable bistable valve with tunable behaviours for controlling soft pneumatic robots. As an integrable control device, the valve stores one bit of binary information without requiring a constant energy supply and correspondingly controls a pneumatic chamber. Secondly, in order to reduce the number of valves required to control multi-chamber soft robots, we introduced a modular approach to design multi-channel bistable valves based on the previous work. Thirdly, in order to achieve continuous pressure modulation with integrable devices, we designed a soft proportional valve, utilizing the continuous deformation of Magnetorheological Elastomer (MRE) under magnetic flux. Apart from the analogue activation manner, this design also ensures a fast response time, operating at a time scale of tens of milliseconds, much shorter than the mechanical response time of most soft pneumatic actuators. Fourthly, to achieve onboard proportional control of multi-chamber soft robots, we developed an MRE valve array with an embedded cooling chamber. Physical experiments showed that our MRE valve array ensured the independence and accuracy of each valve unit within it, with a significantly lowered temperature of 73.9 $^o$C under 5 minutes of operation. Lastly, we developed an open-source software toolbox supporting the design of integrable pneumatic logic circuits to enhance their accessibility and performance. The toolbox comes with a graphical user interface (GUI) to take users' desired logic functions in the form of a truth table and a set of 2D space constraints related to the available space onboard the robot. It then schedules the pneumatic circuit which performs the desired computation within the space constraints and produces a 3D-printable CAD file that can be fabricated and used directly. The work presented in this thesis enables the community to simplify the process of integrating control devices into soft pneumatic robots, thereby paving the way for a new generation of fully untethered and autonomous soft robots

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

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