Hard-Stop Synthesis for Multi-DOF Compliant Mechanisms

Compliant mechanisms have significant potential in precision applications due to their ability to guide motion without contact. However, an inherent vulnerability to fatigue and mechanical failure has hindered the translation of compliant mechanisms to real-world applications. This is particularly challenging in service environments where loading is complex and uncertain, and the cost of failure is high. In such cases, mechanical hard stops are critical to prevent yielding and buckling. Conventional hard-stop designs, which rely on stacking single-DOF limits, must be overly restrictive in multi-DOF space to guarantee safety in the presence of unknown loads. In this study, we present a systematic design synthesis method to guarantee overload protection in compliant mechanisms by integrating coupled multi-DOF motion limits within a single pair of compact hard-stop surfaces. Specifically, we introduce a theoretical and practical framework for optimizing the contact surface geometry to maximize the mechanisms multi-DOF working space while still ensuring that the mechanism remains within its elastic regime. We apply this synthesis method to a case study of a caged-hinge mechanism for orthopaedic implants, and provide numerical and experimental validation that the derived design offers reliable protection against fatigue, yielding, and buckling. This work establishes a foundation for precision hard-stop design in compliant systems operating under uncertain loads, which is a crucial step toward enabling the application of compliant mechanisms in real-world systems.

Self-Deployable, Adaptive Soft Robots Based on Contracting-Cord Particle Jamming

We developed a new class of soft locomotive robots that can self-assemble into a preprogrammed configuration and vary their stiffness afterward in a highly integrated, compact body using contracting-cord particle jamming (CCPJ). We demonstrate this with a tripod-shaped robot, TripodBot, consisting of three CCPJ-based legs attached to a central body. TripodBot is intrinsically soft and can be stored and transported in a compact configuration. On site, it can self-deploy and crawl in a slip-stick manner through the shape morphing of its legs; a simplified analytical model accurately captures the speed. The robot's adaptability is demonstrated by its ability to navigate tunnels as narrow as 61 percent of its deployed body width and ceilings as low as 31 percent of its freestanding height. Additionally, it can climb slopes up to 15 degrees, carry a load of 5 grams (2.4 times its weight), and bear a load 9429 times its weight.

Self-deployable contracting-cord metamaterials with tunable mechanical properties

Recent advances in active materials and fabrication techniques have enabled the production of cyclically self-deployable metamaterials with an expanded functionality space. However, designing metamaterials that possess continuously tunable mechanical properties after self-deployment remains a challenge, notwithstanding its importance. Inspired by push puppets, we introduce an efficient design strategy to create reversibly self-deployable metamaterials with continuously tunable post-deployment stiffness and damping. Our metamaterial comprises contracting actuators threaded through beads with matching conical concavo-convex interfaces in networked chains. The slack network conforms to arbitrary shapes, but when actuated, it self-assembles into a preprogrammed configuration with beads gathered together. Further contraction of the actuators can dynamically tune the assembly's mechanical properties through the beads' particle jamming, while maintaining the overall structure with minimal change. We show that, after deployment, such metamaterials exhibit pronounced tunability in bending-dominated configurations: they can become more than 35 times stiffer and change their damping capability by over 50%. Through systematic analysis, we find that the beads'conical angle can introduce geometric nonlinearity, which has a major effect on the self-deployability and tunability of the metamaterial. Our work provides routes towards reversibly self-deployable, lightweight, and tunable metamaterials, with potential applications in soft robotics, reconfigurable architectures, and space engineering.