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Printed helicoids with embedded air channels make sensorized segments for soft continuum robots

Annan Zhang, Hanna Matusik, Miguel Flores-Acton, Emily R. Sologuren, Joshua Jacob, Daniela Rus

Abstract

Soft robots enable safe, adaptive interaction with complex environments but remain difficult to sense and control due to their highly deformable structures. Architected soft materials such as helicoid lattices offer tunable stiffness and strength but are challenging to instrument because of their sparse geometry. We introduce a fabrication method for embedding air channels into helicoid-based soft continuum robots. Multi-material segments fabricated via vision-controlled jetting in a single print interface with PCBs housing miniature pressure sensors and IMUs for distributed deformation sensing. We characterize the mechanical properties of four helicoid designs and validate the sensor response to fundamental deformation modes. To demonstrate the platform's scalability, we construct and mechanically evaluate a meter-scale, 14-DoF cable-driven soft arm capable of open-loop trajectory tracking and object grasping, with tactile-based stiffness detection demonstrated using the gripper sensors. This approach establishes a scalable fabrication strategy for sensorized architected materials in large-scale soft robotic systems.

Printed helicoids with embedded air channels make sensorized segments for soft continuum robots

Abstract

Soft robots enable safe, adaptive interaction with complex environments but remain difficult to sense and control due to their highly deformable structures. Architected soft materials such as helicoid lattices offer tunable stiffness and strength but are challenging to instrument because of their sparse geometry. We introduce a fabrication method for embedding air channels into helicoid-based soft continuum robots. Multi-material segments fabricated via vision-controlled jetting in a single print interface with PCBs housing miniature pressure sensors and IMUs for distributed deformation sensing. We characterize the mechanical properties of four helicoid designs and validate the sensor response to fundamental deformation modes. To demonstrate the platform's scalability, we construct and mechanically evaluate a meter-scale, 14-DoF cable-driven soft arm capable of open-loop trajectory tracking and object grasping, with tactile-based stiffness detection demonstrated using the gripper sensors. This approach establishes a scalable fabrication strategy for sensorized architected materials in large-scale soft robotic systems.
Paper Structure (19 sections, 6 equations, 11 figures, 1 table)

This paper contains 19 sections, 6 equations, 11 figures, 1 table.

Table of Contents

  1. Introduction
  2. Related Work
  3. Contributions
  4. Hardware Design
  5. Helicoid Design
  6. Embedded Air Channel Design
  7. Helicoid Fabrication
  8. PCB and Readout Electronics
  9. Experimental Evaluation
  10. Mechanical Characterization
  11. Sensor Characterization
  12. 14-DoF Robot Arm
  13. Gripper
  14. Motor Base and Assembly
  15. Experiments
  16. ...and 4 more sections

Figures (11)

  • Figure 1: Overview of the multi-material soft continuum robot made of helicoid segments with embedded air channels.
  • Figure 2: Helicoid construction showing annular sector parameters, helical sweep with axial rise and twist, and repeated structure.
  • Figure 3: Comparison of the four helicoid designs showing the variation in strut thickness and spacing.
  • Figure 4: Left: N6 segment with rigid end plates and air channels. Right: Transparent view showing air channel routing through the helicoid structure.
  • Figure 5: Left: Custom PCB with integrated pressure sensors and IMU. Right: CAN-USB adapter for interfacing with a host computer.
  • ...and 6 more figures