Organizations: Department of Mechanical Engineering and Materials Science, Duke University, Durham, NC 27708, USA. · Department of Biomedical Engineering, Duke University, Durham, NC 27708, USA · Department of Neurology, Duke University School of Medicine, Durham, NC 27710, USA. · Department of Biostatistics and Bioinformatics, Duke University, Durham, NC 27710, USA. · Department of Electrical and Computer Engineering, Duke University, Durham, NC 27708, USA.
Abstract
Reliable real-time 3D shape sensing is essential for robust control and interpretation of deformable systems during motion. Existing vision-based approaches require line-of-sight and complex instrumentation, limiting operation in occluded and space-constrained settings. Here, we introduce a scalable, skin-like sensor that reconstructs its continuous 3D deformation in real time from distributed strain measurements. The device embeds a 2D array of mirror-stacked, printed oxidized eutectic gallium-indium (o-EGaIn) strain gauges within an elastomeric film to measure off-neutral-axis strains. Combined with a mechanics-informed observation model and a fast optimization routine, the system estimates local curvature, elongation, offset, and orientation under concurrent stretching, bending, and indentation, enabling reconstruction of complex surfaces. A 5-by-5 array with a 12 mm pitch achieves a mean surface reconstruction error of 0.62 mm with 0.1s latency across all tested scenarios. When conforming to complex surfaces, the sensor provides fast 3D shape mapping of the underlying geometry. Demonstrations involving palm gesturing, finger indentation, and contact-induced balloon deformation highlight utility for epidermal motion tracking, haptic interaction, and intraoperative monitoring.
Reconstructing the three-dimensional (3D) geometry of object surfaces is essential for robot perception, yet vision-based approaches degrade under low illumination or occlusion. This limitation motivates the design of a proprioceptive membrane that conforms to the surface of interest and infers 3D geometry by reconstructing its own deformation. Conventional deformation-aware membranes typically rely on resistive, capacitive, or magneto-sensitive mechanisms, but can suffer from structural complexity, limited compliance during large-scale deformation, and susceptibility to electromagnetic interference. This work presents a soft, flexible, and stretchable proprioceptive silicone membrane based on optical waveguide sensing. The membrane integrates edge-mounted LEDs and centrally-distributed photodiodes (PDs) within a multilayer elastomeric composite. Rich deformation-dependent light-intensity signals are decoded by a data-driven model to recover the membrane geometry. Real-time reconstruction is demonstrated on a customized 140 mm square membrane at an end-to-end update rate of 90 Hz, achieving an average reconstruction error of 1.307 mm for out-of-plane deformation of up to 25 mm. The proposed sensor also demonstrates accurate reconstruction under large in-plane deformation, achieving reliable shape recovery up to 75% strain with an average Chamfer distance of 1.214 mm. The proposed framework provides a scalable, robust, and low-profile solution for global shape perception in deformable robotic systems.
Most shape reconstruction methods assume measurements defined over planar sensing domains, such as RGB images or depth maps. In this paper, we use a curved capacitive textile as a shape sensor, treating its surface as a non-planar sensing manifold. Each scan is represented as a capacitive proximity field on this manifold, induced by the interaction between the curved electrode layout and nearby object geometry. We introduce a multi-view feedforward reconstruction model that aggregates these fields across known sensor views and recovers the observed object shape. Simulated and physical experiments demonstrate robust reconstruction from capacitive proximity signals acquired on curved sensing surfaces, pointing toward a new route to robotic near-field geometric awareness via embodied sensing.
Curved tactile fingertips for dexterous manipulation must resolve fine contact geometry, distinguish normal and tangential loads, and capture transient signals. Existing curved vision-based tactile sensors struggle to combine accurate 3D reconstruction, three-axis force estimation, and high-speed processing in a compact form. This article presents FasTac, a curved vision-based tactile sensor integrating multispectral photometric stereo, dynamic-convolution force estimation, and hardware acceleration on a field-programmable gate array (FPGA). Single-image-sensor simultaneous multispectral imaging provides spatially aligned observations for robust surface normal estimation, followed by boundary-prior fast Poisson depth reconstruction. HyperForce uses position-aware dynamic convolution to model the spatially nonuniform mechanical response of curved elastomers and estimate three-axis forces. The complete image-to-normal-force pipeline is deployed on an FPGA. Experiments show that near-infrared (NIR) illumination and the boundary prior decrease depth mean absolute error (MAE) from 0.2730 mm to 0.0415 mm; HyperForce achieves normalized mean absolute error (NMAE) values of 2.74% and 2.39% for normal and shear forces, respectively; and FPGA deployment shortens processing latency from 3.26 ms on the GPU to 1.09 ms. Multi-object reconstruction, feedback grasping, and vibration measurement validate fine geometric perception, stable force feedback, and dynamic contact sensing.