Fly, Drive, Reconfigure: A Modular Reconfigurable Aerial-Ground Platform for Field Operations

Modular Aerial Robot Systems (MARS) consist of multiple drone modules that are physically bound together to form a single structure for flight. Exploiting structural redundancy, MARS can be reconfigured into different formations to mitigate unit or rotor failures and maintain stable flight. Prior work on MARS self-reconfiguration has solely focused on maximizing controllability margins to tolerate a single rotor or unit fault for rectangular-shaped MARS. We propose TransforMARS, a general fault-tolerant reconfiguration framework that transforms arbitrarily shaped MARS under multiple rotor and unit faults while ensuring continuous in-air stability. Specifically, we develop algorithms to first identify and construct minimum controllable assemblies containing faulty units. We then plan feasible disassembly-assembly sequences to transport MARS units or subassemblies to form target configuration. Our approach enables more flexible and practical feasible reconfiguration. We validate TransforMARS in challenging arbitrarily shaped MARS configurations, demonstrating substantial improvements over prior works in both the capacity of handling diverse configurations and the number of faults tolerated. The videos and source code of this work are available at https://github.com/RuiHuangNUS/TransforMARS

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.

The tight coupling of subsystems in most robots, though a natural consequence of their complexity, leads to monolithic designs that are time-consuming and difficult to adapt after initial deployment. To address this challenge, we present a framework and supporting abstractions for recomposition during runtime that enable robots to quickly integrate previously unseen modular software, hardware, and compute payloads. Our approach allows non-expert users to quickly add new capabilities in the field through a true plug-and-play process. Crucially, new resources are not only immediately available to a host robot but are also shared with distributed peers, enabling compute-constrained systems to access powerful new remote capabilities. Our framework reduces reconfiguration time to a matter of minutes with no developer intervention, in stark contrast to the hours of expert effort often required for traditional manual integration. We demonstrate our method in two disaster response scenarios, including radioactive source localization at an operational nuclear reactor facility and a thermal-guided search for people in dark, difficult-to-reach spaces. These demonstrations show how in-field recomposition provides timely, flexible, and accessible adaptation to dynamic requirements, representing a critical step toward creating robots that can quickly evolve alongside the tasks, technologies, and environments they support.