Geometry-based pneumatic actuators for soft robotics

Soft pneumatic actuators enable safe human-machine interaction with lightweight and powerful applied parts. On the other side, they suffer design limitations as regards complex actuation patterns, including minimum bending radii, multi-states capabilities and structural stability. We present geometry-based pneumatic actuators (GPAs), a design and implementation approach that introduces constraint layers with configurable CNC heat-sealed chambers. The approach achieves predictable deformation, near-zero bending radii, multi-states actuation, and enables customizable and repeatable complex actuated geometries. Mathematical modeling reveals predictable linear angle transformations and validates nonlinear torque-angle relationships across diverse configurations. We demonstrate versatility of the GPAs approach through three applications: a 49 g wrist exoskeleton reducing muscle activity by up to 51%, a 30.8 g haptic interface delivering 8 N force feedback with fast response, and a 208 g bipedal robot achieving multi-gait locomotion. GPAs establish a configurable platform for next-generation wearable robotics, haptic systems, and soft locomotion devices.