Tendon-Actuated Robots with a Tapered, Flexible Polymer Backbone: Design, Fabrication, and Modeling
Authors: Harald Minde Hansen, Nandita Gallacher, Nicholas B. Andrews, Kristin Y. Pettersen, Jan Tommy Gravdahl, Mario di Castro
Abstract
This paper presents the design, modeling, and fabrication of 3D-printed, tendon-actuated continuum robots featuring a flexible, tapered backbone constructed from thermoplastic polyurethane (TPU). Our scalable design incorporates an integrated electronics base housing that enables direct tendon tension control and sensing via actuators and compression load cells. Unlike many continuum robots that are single-purpose and costly, the proposed design prioritizes customizability, rapid assembly, and low cost while enabling high curvature and enhanced distal compliance through geometric tapering, thereby supporting a broad range of compliant robotic inspection and manipulation tasks. We develop a generalized forward kinetostatic model of the tapered backbone based on Cosserat rod theory using a Newtonian approach, extending existing tendon-actuated Cosserat rod formulations to explicitly account for spatially varying backbone cross-sectional geometry. The model captures the graded stiffness profile induced by the tapering and enables systematic exploration of the configuration space as a function of the geometric design parameters. Specifically, we analyze how the backbone taper angle influences the robot's configuration space and manipulability. The model is validated against motion capture data, achieving centimeter-level shape prediction accuracy after calibrating Young's modulus via a line search that minimizes modeling error. We further demonstrate teleoperated grasping using an endoscopic gripper routed along the continuum robot, mounted on a 6-DoF robotic arm. Parameterized iLogic/CAD scripts are provided for rapid geometry generation and scaling. The presented framework establishes a simple, rapid, and reproducible pathway from parametric design to controlled tendon actuation for tapered, tendon-driven continuum robots manufactured using fused deposition modeling 3D printers.
Predicting the shape of tendon driven continuum robots (TDCRs) at steady state from actuation remains challenging due to continuous deformation, complex tendon routing, compliance, friction, and fabrication variability. In this paper, we address this problem as kinematic self modeling conditioned on action. We present a lightweight 3D printed TDCR hardware platform and an RGB-D data collection pipeline with multiple cameras, and we learn a point cloud flow matching model that maps motor actuation states to the robot's settled 3D geometry. The model is trained from randomly sampled quasi static configurations and evaluated on test motor commands within the same TDCR design family and actuation range. We compare against prior 3D deformable object and robot self modeling approaches in both MuJoCo simulation and real hardware experiments. Experiments on simulated 2-, 3-, and 5-module TDCRs and real 2- and 3-module robots show improved shape prediction accuracy under CD and EMD metrics. We further show in simulation that the same conditional formulation generalizes to tip payload as a conditioning input, enabling payload conditioned steady-state shape prediction. These results demonstrate a data driven self modeling framework for quasi static TDCR geometry prediction.
Shape and force sensing have long been critical bottlenecks in the development of compact capstan-driven continuum surgical robots, primarily due to the difficulty of obtaining cable tension information within the confined capstan assembly. To overcome these challenges, this paper presents an integrated design-modeling-sensing approach based on the concept of actuation-perception co-design. A compliant element is introduced into the motor mounting bracket of the drive system, enabling micro-deformation under the cable reaction force and thereby allowing real-time cable tension measurement without occupying the compact capstan space. To address the modeling complexity arising from unconventional joint configurations introduced by the spatial cable routing strategy, a parallel computation framework based on a multibody short-thick-beam model is proposed, which captures shear effects in short beam segments and synergistic multi-cable interactions while achieving real-time performance. Building on this framework, stable shape and force sensing is achieved by incorporating a proximal multi-axis force/torque sensor as an additional measurement anchor. Following this design-modeling-sensing framework, capstan-driven continuum surgical robots with single- and dual-segment configurations are developed. Experimental results validate the proposed framework in both single- and dual-segment continuum robots, demonstrating real-time tip pose estimation together with contact force and location perception. By enabling cable tension feedback without compromising the compact capstan architecture, the proposed framework makes integrated perception feasible for capstan-driven continuum surgical robots.
Developing dynamic models for tendon-driven continuum robots is challenging due to their nonlinear, high-dimensional, and friction-dominated dynamics. This paper presents a comparative study of data-driven system identification methods, including N4SID, ARX, and SINDYc, for modeling a tendon-actuated continuum robot with rolling joints developed at CERN. Despite the high number of joints of the robot, experimental analysis reveals that a two-degree-of-freedom dynamic model can accurately capture the system dynamics, owing to strong kinematic dependencies between the joints. The models are validated against experimental data, and used in the design of a model predictive controller, demonstrating their feasibility for real-time control.
Harald Minde Hansen, Bjørn Kåre Sæbø, Kristin Y. Pettersen +2