Curvature by Design: A Support Structure for Continuum Robots

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.

Supportive continuum robots (SCRs) enhance the load-bearing capability of an operative continuum robot by mechanically coupling it with a supportive arm. However, their passive stiffness is determined by the mechanical configuration and cannot be adjusted online for varying payloads or interaction forces. Active stiffness control is therefore needed to regulate the load response and maintain positioning accuracy. Meanwhile, the closed-chain structure introduces kinematic constraints that complicate task-space regulation and stiffness control. This paper presents an active task-space stiffness control framework for a tendon-driven SCR. An existing geometric variable strain model describes the closed-chain dynamics, which are projected onto the constraint-consistent motion subspace. A projected sliding mode controller regulates the operative arm tip while preserving the constraints, and closed-loop stability is established through Lyapunov analysis. After position regulation, active apparent stiffness is introduced through a virtual Cartesian spring based on position-error feedback to shape the force--displacement response. The framework is evaluated in simulation and experimentally validated under prescribed external loads and different desired configurations. Results show that increasing the commanded stiffness gain reduces load-induced tip deflection and increases apparent directional stiffness, thereby improving load resistance and positioning robustness under external loading.

Real-time motion generation for tendon-driven continuum robots requires accurate modeling of nonuniform bending and whole-body collision avoidance. This paper presents a unified actuation-space framework for planar multi-segment tendon-driven continuum robots. An energy-based variable-curvature model captures spatially varying tendon spacing and bending stiffness and provides analytical Jacobians for differential inverse kinematics and safety monitoring. A multipoint CBF-QP enforces backbone clearance under obstacle motion and actuation-velocity bounds, while its decision dimension depends only on the number of independently actuated segments. The model closely agrees with GVS references, with a maximum curvature error of $5.223 \times 10^{-2}\,\mathrm{m}^{-1}$. Over 100 MuJoCo trials, the proposed method achieves collision-free success rates of 96% and 100% in static and dynamic scenarios, respectively, compared with approximately 60% and 80% without CBF constraints. Hole-traversal tests further demonstrate safe motion in constrained environments. With 600 backbone monitoring points, the mean control-step time is 6.66 ms, demonstrating real-time whole-body safe motion generation.