Shape Sensing of Continuum Robots using Direct Laser Writing

Continuum robots offer a promising approach for minimally invasive and natural-orifice surgical procedures due to their inherent compliance and dexterity. However, this flexibility also makes estimating the current shape of the robot challenging. Several approaches have been used to reconstruct the shape of these robots, including imaging, optical sensing, magnetic sensing, and resistive sensing. Strain sensors fabricated using direct laser writing (DLW) could provide an alternative sensing method. This technique involves using a laser to induce carbonization of certain polymers to create graphene patterns, such as strain sensors. In this paper, we demonstrate how a flexible continuum joint and a DLW sensor can be machined as one monolithic structure using the same laser and the same setup. The fabricated sensors are characterized using linear and nonlinear models, which are used to predict the joint angle with error as low as 1.76 degrees. Furthermore, we demonstrate how a DLW sensor can be used to implement closed-loop control in a robotic joint, achieving tracking error under 3 degrees.

Design of a Polymer-based Steerable Cannula for Neurosurgical Applications

Robotically steerable compliant surgical tools offer several advantages over rigid tools, including enhanced dexterity, reduced tissue damage, and the ability to generate non-linear trajectories in minimally invasive neurosurgical procedures. Many existing robotic neurosurgical tools are designed using stainless steel or nitinol materials. Using polymer-based materials instead can offer advantages such as reduced interference in magnetic resonance imaging, enhanced safety for guiding electrically powered instruments, and reduced tissue damage due to inherent compliance. Several polymer materials have been used in robotic surgical applications, such as polyimide, polycarbonate, and elastic resin. Various fabrication strategies have also been proposed, including standard microfabrication techniques, thermal drawing, and 3-D printing. In our previous work, a tendon-driven, notched-tube was designed for several neurosurgical robotic tools, utilizing laser micromachining to reduce the stiffness of the tube in certain directions. This fabrication method is desirable because it has a single-step process, has high precision, and does not require a cleanroom or harsh chemicals. Past studies have explored laser-micromachining of polymer material for surgical applications such as stent fabrication. In this work, we explore extending the use of the laser micromachining approach to the fabrication of polyimide (PI) robotically steerable cannulas for neurosurgical applications. Utilizing the method presented in this work, we fabricated joints as small as 1.5 mm outer diameter (OD). Multiple joints were fabricated using PI tubes of different ODs, and the loading behavior of the fabricated joints was experimentally characterized.