Multilaminate piezoelectric polymer actuators for insect-scale softrobots

Modern flapping-wing insect-scale air vehicles display agility similar to that of their insect counterparts; however, these impressive maneuvers are only possible with off-board sensors like optical tracking cameras. In this manuscript, we introduce two embedded proprioceptive sensors for insect-scale aerial robots: thin film piezoelectric polymers integrated directly into a driving actuator and a pitching hinge which track stroke and pitch angle, respectively. We fabricate the aforementioned size-agnostic mechanically intelligent structures (sensor-actuator, sensor-flexure) using laminate stack fabrication methods. Chirp experiments with our sensors integrated into an insect-size flapping-wing robot show accurate tracking of stroke (RMSE = 0.44 deg) and pitch (RMSE = 2.44 deg) angles in the relevant frequency range. As the first step towards demonstrating the utility of these sensors for enabling numerous onboard autonomy applications, including closed-loop wingbeat control and sensor fusion with existing insect-scale sensor suites for more accurate proprioception and localization, we show one application for each sensor. The proprioceptive hinge enables collision detection, reducing the chance of permanent damage if the robot's wing collides with an object. The proprioceptive actuator enables asynchronous flapping, which is hypothesized to increase adaptability and efficiency in insects and robots alike. A microrobot equipped with our proprioceptive actuator allows us to test these hypotheses with potential for improving flapping aerial robot performance. We foresee proprioceptive sensors having an important role in progressing both the fields of insect-scale aerial robots and robo-physics due to the bio-inspired nature and high integration level of our sensors.

Functional magnetic composites capable of large deformation, load bearing, and multifunctional motion are essential for next-generation adaptive soft robots. Here, we present muscle-inspired magnetic actuators (MMA), additively manufactured from a thermoplastic/permanent magnet polyurethane/Nd2Fe14B (TPU/MQP-S) composite using laser powder bed fusion (LPBF). By tuning the laser-energy scale between 1.0 and 3.0, both mechanical stiffness and magnetic response are precisely controlled: the tensile strength increases from 0.28 to 0.99 MPa while maintaining 30-45% elongation at break. This process enables the creation of 0.5 mm-thick flexural hinges, which reversibly bend and fold under moderate magnetic fields without damage. Two actuator types are reported showing the system versatility. The elongated actuator with self-weight of 1.57 g, magnetized in its contracted state, achieves linear contraction under a 500 mT field, lifting 50 g (32x its own weight) and sustaining performance over at least 50 cycles. Equipped with anisotropic frictional feet, it supports movement of a magnetic crawling robot that achieves up to 100% locomotion success on textured substrates. The expandable actuator exhibits reversible opening and closing under a 300 mT field, reliably grasping and releasing different objects, including soft berries and rigid 3D printed geometries. It can also anchor in a tube while holding suspended 50 g loads. This work demonstrates a LPBF-based strategy to program both stiffness and magnetization within a single material system, enabling remotely driven, reconfigurable, and fatigue-resistant soft actuators. The approach opens new possibilities for force controlled, multifunctional magnetic soft robots for adaptive gripping, locomotion, and minimally invasive manipulation of biomedical tools.

Short lifetime under high electrical fields hinders the widespread robotic application of linear dielectric elastomer actuators (DEAs). Systematic scanning is difficult due to time-consuming per-sample testing and the high-dimensional parameter space affecting performance. To address this, we propose an optimization pipeline enabled by a novel testing robot capable of scanning DEA lifetime. The robot integrates electro-mechanical property measurement, programmable voltage input, and multi-channel testing capacity. Using it, we scanned the lifetime of Elastosil-based linear actuators across parameters including input voltage magnitude, frequency, electrode material concentration, and electrical connection filler. The optimal parameter combinations improved operational lifetime under boundary operating conditions by up to 100% and were subsequently scaled up to achieve higher force and displacement output. The final product demonstrated resilience on a modular, scalable quadruped walking robot with payload carrying capacity (>100% of its untethered body weight, and >700% of combined actuator weight). This work is the first to introduce a self-driving lab approach into robotic actuator design.