A Morphing Aerial Robot With Thruster-Integrated Flexible Continuum Links for Shape Adaptive Aerial Manipulation

Infrastructure maintenance, contact-based inspection, and emergency response can benefit from aerial vehicles that act as a flying human hand with extreme maneuverability, manipulation, and resiliency (MMR): maneuverability to fly in arbitrary orientations to reach remote and tight locations; manipulation to point sensors, turn valves, and press tools at arbitrary orientations; resiliency to maintain accurate motion and force control despite disturbances from arbitrary directions, such as wind, ground effects, and friction. Realizing MMR on aerial vehicles requires not only omnidirectional flight; it also requires (I) vectoring of maximum thrust in any direction, to maximize capacity for contact-force application and disturbance rejection, (II) global stability, to enable control over any orientation/position, and (III) compact, standard designs that build upon platforms such as quadrotors to inherit technological know-how. No current aerial vehicle simultaneously enables I--III, due to structural and control limitations that constrain actuation. We present MorphQuad: a morphable quadrotor that enjoys MMR. Key to our approach is a hardware and control co-design: on hardware, we independently articulate each of the four rotor systems via two-axis gimbals; on control, we introduce globally-stable control, and energy-optimal thrust allocation that permits inter-rotor thrust cancellations only to avoid downwash interference and gimbal lock. With fully-onboard autonomy, MorphQuad demonstrates multi-revolution rotation while translating or hovering, for pipe inspection and target tracking (maneuverability); valve turning, perching, and object pressing and pushing with human-level strengths (manipulation); and wind rejection from any direction, even directed to a single rotor, and push-pull recovery (resiliency).

Multi-link aerial robots can actively deform their articulated structures during flight, giving them strong potential for aerial manipulation. However, they still face substantial challenges in contact-rich aerial manipulation tasks such as surface sliding, which requires both disturbance robustness and compliance to uncertain surface geometry. Force-control strategies such as impedance and admittance control are commonly employed to address these requirements. Although impedance control can provide disturbance-resistant interaction and admittance control can offer compliant adaptation, their opposite force--motion causalities prevent their simultaneous implementation when applied through the same actuation source, such as the rotor thrusts used by conventional aerial robots. To overcome this limitation, we propose a hybrid impedance--admittance control strategy for a multi-link aerial robot. The articulated morphology enables a functional separation of force and motion regulation across joint and rotor actuation sources. In this framework, admittance behavior is generated through joint angle regulation to enhance adaptive interaction, while impedance behavior is achieved by modulating rotor thrust to regulate the sliding motion. This structural coordination allows the robot to leverage the complementary strengths of both control paradigms. As a result, the multi-link aerial robot achieves resilient and adaptive surface sliding. Experimental results demonstrate robust and compliant sliding performance on unknown surfaces.

Multirotor aerial robots excel at maneuvering in three-dimensional space, and recent advances enable nimble navigation in cluttered and confined environments, especially for small airframes. By contrast, platforms built for high-altitude work tend to be larger to deliver high thrust for stable physical interaction with the environment. However, these conflicting design requirements create a long-standing trade-off between nimble navigation and robust aerial manipulation. Here, we present LEGION units, which are reconfigurable modular aerial robots capable of in-flight self-assembly for cooperative manipulation, drawing inspiration from the self-organized collectives formed by ants. Each unit retains nimble maneuverability while joint-equipped docking interfaces at both ends enable end-to-end self-assembly into a flying manipulator. We show that multiple units autonomously dock in flight; once latched, they maintain a zero-clearance interlock by controlling the contact force and torque, enabling reliable aggregation and articulated motion even outdoors. We further show that self-reconfigurability enables morphological switching between nimble individual flight and collective articulated manipulation, while realizing core in-flight manipulation primitives including pushing, pulling, rotating, grasping, and carrying. LEGION's self-organization enables aerial robots, especially in swarms, to shift from passive observers to active participants in their environment, broadening the scope of aerial physical interaction.