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.
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.
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.
Harald Minde Hansen, Nandita Gallacher, Nicholas B. Andrews +3
In this paper, we discuss a novel continuum robot design that enables the online tuning of the magnetic response at its tip. The proposed method allows for the change of both effective magnetic direction and intensity, introducing steering DOF without the need to control the external fields. This is unattainable with classical designs, which rely on fixed internal magnetic content and steer solely under the effect of a controllable magnetic field. The proposed robot design can be used in both controllable and fixed magnetic fields, potentially widening the clinical applicability of these robots. We experimentally show a max tip deflection of 33.8 mm from the resting state (23 % of the length of the robot). We discuss a model based on modified beam theory that captures the mechanical behavior of the continuum robot, with a mean absolute tip tracking error of 1.86 mm (1.2 % of the length) and maximum errors of less than 4.8 mm (3.2 % of the length) for all experimental points.