Shape Sensing of Continuum Robots using Direct Laser Writing

Continuum robots enable smooth shape morphing and safe interaction in confined environments. However, most existing systems are task-specific and depend on external sensing infrastructure, limiting their adaptability and real-world deployment. This paper presents a self-contained modular continuum robotic platform that combines mechanical reconfigurability with onboard pose estimation. The robot is constructed from interchangeable continuum joints with analytically precomputed stiffness, allowing rapid assembly and direct programming of the robot shape. Proprioceptive sensing is achieved using magnetic sensors and a modular learning-based framework, where a single model is trained per joint and reused across configurations. The system is experimentally validated in real world, demonstrating self-sensing capabilities and adaptation without external tracking.

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.

Reconstructing the shape of continuum manipulators from sparse, noisy sensor data is a challenging task, owing to the infinite-dimensional nature of such systems. Existing approaches broadly trade off between parametric methods that yield compact state representations but lack probabilistic structure, and Cosserat rod inference on factor graphs, which provides principled uncertainty quantification at the cost of a state dimension that grows with the spatial discretization. This letter combines the strength of both paradigms by estimating the coefficients of a low-dimensional Geometric Variable Strain (GVS) parameterization within a factor graph framework. A novel kinematic factor, derived from the Magnus expansion of the strain field, encodes the closed-form rod geometry as a prior constraint linking the GVS strain coefficients to the backbone pose variables. The resulting formulation yields a compact state vector directly amenable to model-based control, while retaining the modularity, probabilistic treatment and computational efficiency of factor graph inference. The proposed method is evaluated in simulation on a 0.4 m long tendon-driven continuum robot under three measurement configurations, achieving mean position errors below 2 mm for all three scenarios and demonstrating a sixfold reduction in orientation error compared to a Gaussian process regression baseline when only position measurements are available.