Form-Fitting, Large-Area Sensor Mounting for Obstacle Detection

We introduce a low-cost method for mounting sensors onto robot links for large-area sensing coverage that does not require the sensor's positions or orientations to be calibrated before use. Using computer aided design (CAD), a robot skin covering, or skin unit, can be procedurally generated to fit around a nondevelopable surface, a 3D surface that cannot be flattened into a 2D plane without distortion, of a robot. The skin unit embeds mounts for printed circuit boards of any size to keep sensors in fixed and known locations. We demonstrate our method by constructing point cloud images of obstacles within the proximity of a Franka Research 3 robot's operational environment using an array of time of flight (ToF) imagers mounted on a printed skin unit and attached to the robot arm.

GenTact Toolbox: A Computational Design Pipeline to Procedurally Generate Context-Driven 3D Printed Whole-Body Tactile Skins

Developing whole-body tactile skins for robots remains a challenging task, as existing solutions often prioritize modular, one-size-fits-all designs, which, while versatile, fail to account for the robot's specific shape and the unique demands of its operational context. In this work, we introduce the GenTact Toolbox, a computational pipeline for creating versatile whole-body tactile skins tailored to both robot shape and application domain. Our pipeline includes procedural mesh generation for conforming to a robot's topology, task-driven simulation to refine sensor distribution, and multi-material 3D printing for shape-agnostic fabrication. We validate our approach by creating and deploying six capacitive sensing skins on a Franka Research 3 robot arm in a human-robot interaction scenario. This work represents a shift from one-size-fits-all tactile sensors toward context-driven, highly adaptable designs that can be customized for a wide range of robotic systems and applications.