Integrated Design and Fabrication of Pneumatic Soft Robot Actuators in a Single Casting Step

Bio-inspired soft robots have already shown the ability to handle uncertainty and adapt to unstructured environments. However, their availability is partially restricted by time-consuming, costly and highly supervised design-fabrication processes, often based on resource intensive iterative workflows. Here, we propose an integrated approach targeting the design and fabrication of pneumatic soft actuators in a single casting step. Molds and sacrificial water-soluble hollow cores are printed using fused filament fabrication (FFF). A heated water circuit accelerates the dissolution of the core's material and guarantees its complete removal from the actuator walls, while the actuator's mechanical operability is defined through finite element analysis (FEA). This enables the fabrication of actuators with non-uniform cross sections under minimal supervision, thereby reducing the number of iterations necessary during the design and fabrication processes. Three actuators capable of bending and linear motion were designed, fabricated, integrated and demonstrated as three different bio-inspired soft robots, an earthworm-inspired robot, a four-legged robot, and a robotic gripper. We demonstrate the availability, versatility and effectiveness of the proposed methods, contributing to accelerating the design and fabrication of soft robots. This study represents a step toward increasing the accessibility of soft robots to people at a lower cost.

Integrated Design Fabrication and Control of a Bioinspired Multimaterial Soft Robotic Hand

Machines that mimic humans have inspired scientists for centuries. Bio-inspired soft robotic hands are a good example of such an endeavor, featuring intrinsic material compliance and continuous motion to deal with uncertainty and adapt to unstructured environments. Recent research led to impactful achievements in functional designs, modeling, fabrication, and control of soft robots. Nevertheless, the full realization of life-like movements is still challenging to achieve, often based on trial-and-error considerations from design to fabrication, consuming time and resources. In this study, a soft robotic hand is proposed, composed of soft actuator cores and an exoskeleton, featuring a multi-material design aided by finite element analysis (FEA) to define the hand geometry and promote finger's bendability. The actuators are fabricated using molding and the exoskeleton is 3D-printed in a single step. An ON-OFF controller keeps the set fingers' inner pressures related to specific bending angles, even in the presence of leaks. The FEA numerical results were validated by experimental tests, as well as the ability of the hand to grasp objects with different shapes, weights and sizes. This integrated solution will make soft robotic hands more available to people, at a reduced cost, avoiding the time-consuming design-fabrication trial-and-error processes.

A Flexible Piezoresistive/Self-Capacitive Hybrid Force and Proximity Sensor to Interface Collaborative Robots

Force and proximity sensors are key in robotics, especially when applied in collaborative robots that interact physically or cognitively with humans in real unstructured environments. However, most existing sensors for use in robotics are limited by: 1) their scope, measuring single parameters/events and often requiring multiple types of sensors, 2) being expensive to manufacture, limiting their use to where they are strictly necessary and often compromising redundancy, and 3) have null or reduced physical flexibility, requiring further costs with adaptation to a variety of robot structures. This paper presents a novel mechanically flexible force and proximity hybrid sensor based on piezoresistive and self-capacitive phenomena. The sensor is inexpensive and easy to apply even on complex-shaped robot structures. The manufacturing process is described, including controlling circuits, mechanical design, and data acquisition. Experimental trials featuring the characterisation of the sensor were conducted, focusing on both force-electrical resistance and self-capacitive proximity response. The sensor's versatility, flexibility, thinness (1 mm thickness), accuracy (reduced drift) and repeatability demonstrated its applicability in several domains. Finally, the sensor was successfully applied in two distinct situations: hand guiding a robot (by touch commands), and human-robot collision avoidance (by proximity detection).