A Soft Robotic Demonstration in the Stratosphere

Modern robots embody power and precision control. Yet, as robots undertake tasks that apply forces on humans, this power brings risk of injury. Soft robotic actuators use deformation to produce smooth, continuous motions and conform to delicate objects while imparting forces capable of safely pushing humans. This thesis presents strategies for the design, modeling, and strain-based control of human-safe elastomeric soft pneumatic actuators (SPA) for force generation, focusing on embodied mechanical response to simple pressure inputs. We investigate electroadhesive (EA) strain limiters for variable shape generation, rapid force application, and targeted inflation trajectories. We attach EA clutches to a concentrically strain-limited elastomeric membrane to alter the inflation trajectory and rapidly reorient the inflated shape. We expand the capabilities of EA for soft robots by encasing them in elastomeric sheaths and varying their activation in real time, demonstrating applications in variable trajectory inflation under identical pressure sweeps. We then address the problem of trajectory control in the presence of external forces by modeling the pressure-trajectory relationship for a concentrically strain-limited class of silicone actuators. We validate theoretical models based on material properties and energy minimization using active learning and automated testing. We apply our ensemble of neural networks for inverse membrane design, specifying quasi-static mass lift trajectories from a simple pressure sweep. Finally, we demonstrate the power of multiple pressure-linked actuators in a proof-of-concept mannequin leg lift.

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.

Integrating silicone with non-extensible materials is a common strategy used in the fabrication of fluidically-driven soft actuators, yet conventional approaches often rely on irreversible adhesives or embedding processes that are labor-intensive and difficult to modify. This work presents silicone-glossy paper bonding (SGB), a rapid, adhesive-free, and solvent-reversible bonding approach that forms robust silicone-paper interfaces simply through contact. The SGB interface withstands high mechanical loads (shear strength > 61 kPa) and can be fully detached and reassembled via ethanol immersion without loss of performance, enabling component reuse and rapid redesign. Characterization studies indicate that surface functional groups primarily govern adhesion on the glossy paper and the modulus of the silicone, while durability and environmental response clarify the conditions for reversible debonding. The results further suggest a synergistic interaction of hydrogen bonding and oligomer diffusion, yielding strong yet reconfigurable adhesion. Soft actuators fabricated using SGB design exhibit equal or greater performance compared to conventional embedded-layer design and enable programmable actuation modes, including contraction, bending, and twisting. By simplifying fabrication while supporting reuse and rapid iteration, SGB offers a scalable and sustainable platform for rapid prototyping in soft robotics.