Design and Fabrication of a Spin Coater with In-Situ Optical Measurement for Soft Thin Films

Bioprinting is emerging as a tissue engineering technique to replace common treatment methods for large scale injuries. While thickness of the BioPrinted Constructs (BPCs) have shown to be of importance in the cell maturation and integration, the literature lacks a robust, automated, and quantitative method for measuring these metrics. In this paper, we propose a fully automated vision-based method for measuring the thickness of the BPCs with complex geometries. Leveraging the point cloud and RGB images of a structured light 3D camera, our proposed method performs an image-based segmentation for delineating the BPCs from the RGB images, accompanied by novel geometry-based thickness measurement algorithms performed on the point cloud scans. These algorithms combine the segmentation mask with the robot's forward kinematics data and a 3D point cloud scan to precisely measure the aforementioned metrics for complex-shaped BPCs. The proposed method was evaluated in simulation and experimental studies. In simulation studies, the algorithms were used to measure the thickness of some virtually created BPCs with known thickness. The comparison between the measured and true thicknesses demonstrates the high accuracy of the proposed method, achieving mean absolute errors between 0.025 mm and 0.057 mm in simulation at a spatial resolution of 0.1 mm x 0.1 mm per pixel. Furthermore, we successfully deployed the algorithms on our robotic bioprinting setup utilizing a structure light 3D camera, where complex patterns were printed and the developed methods utilized to accurately measure the thickness of printed BPCs.

This letter presents an automated robotic manufacturing system for soft capacitors which operate as actuators and sensors. Emphasis is placed on the two processes that most directly govern device quality, dielectric layer formation by spin coating and carbon nanotube (CNT) electrode application by stamping. Twenty multilayer DEAs, each comprising 12 dielectric layers with a mean thickness of 55.37 +- 2.04 um and 11 alternating CNT electrodes, were fabricated reducing total process time by 14.2% and removing the operator from 56.1% of it.

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.