TO-SoFiT: Topology Optimization of Hydraulic Soft Fish Tail Design for programmable undulating locomotion

Soft robots leverage compliant materials to generate motion through controlled elastic deformation, making them ideal for delicate tasks such as underwater exploration and biomimetic marine systems. Although hydraulic/pneumatic actuation remains pivotal for such systems, the lack of systematic design frameworks has hindered the development of robots capable of complex 3D motion, such as fish-like swimming. This work introduces a topology optimization method to automate the design of a hydraulic soft fish tail, explicitly addressing the design-dependent coupling between fluidic actuation and structural deformation. We use a Darcy law-based model augmented with a drainage term to simulate spatially varying hydraulic pressure loads, translating these into consistent nodal forces via finite element analysis. The employed robust multi-criteria optimization formulation balances deformation efficiency, fluid-structure interaction, geometric manufacturability, and required stiffness for optimizing a bioinspired soft fish tail for 3D swimming kinematics. The optimized tail topology is incorporated into a pneumatic network actuator and computationally validated under various hydraulic loads, achieving tunable undulatory amplitudes and multiaxis bending for depth adjustment. The optimized 2D tail outperforms its rectangular counterpart. By cascading optimized tail segments, we demonstrate programmable swimming patterns in soft robotic fish tails at different hydraulic loads. This work advances the systematic codesign of hydraulic actuators and soft structures, offering a pathway to automate underwater robots with optimized design and vertebrate-like agility in confined aquatic environments. Our implementations and simulations are publicly available at 'https://github.com/PrabhatIn/TO-SoFiT'.