Samuel M. Felton

Methods for Building Self-Folding Machines

Folding robots and metamaterials The same principles used to make origami art can make self-assembling robots and tunable metamaterials—artificial materials engineered to have properties that may not be found in nature (see the Perspective by You). Felton et al. made complex self-folding robots from flat templates. Such robots could potentially be sent through a collapsed building or tunnels and then assemble themselves autonomously into their final functional form. Silverberg et al. created a mechanical metamaterial that was folded into a tessellated pattern of unit cells. These cells reversibly switched between soft and stiff states, causing large, controllable changes to the way the material responded to being squashed. Science, this issue p. 644, p. 647; see also p. 623 Origami techniques are used to develop crawling robots that self-fold from flat-pack designs. Origami can turn a sheet of paper into complex three-dimensional shapes, and similar folding techniques can produce structures and mechanisms. To demonstrate the application of these techniques to the fabrication of machines, we developed a crawling robot that folds itself. The robot starts as a flat sheet with embedded electronics, and transforms autonomously into a functional machine. To accomplish this, we developed shape-memory composites that fold themselves along embedded hinges. We used these composites to recreate fundamental folded patterns, derived from computational origami, that can be extrapolated to a wide range of geometries and mechanisms. This origami-inspired robot can fold itself in 4 minutes and walk away without human intervention, demonstrating the potential both for complex self-folding machines and autonomous, self-controlled assembly.

Self-folding with shape memory composites

Origami-inspired manufacturing can produce complex structures and machines by folding two-dimensional composites into three-dimensional structures. This fabrication technique is potentially less expensive, faster, and easier to transport than more traditional machining methods, including 3-D printing. Self-folding enhances this method by minimizing the manual labor involved in folding, allowing for complex geometries and enabling remote or automated assembly. This paper demonstrates a novel method of self-folding hinges using shape memory polymers (SMPs), paper, and resistive circuits to achieve localized and individually addressable folding at low cost. A model for the torque exerted by these composites was developed and validated against experimental data, in order to determine design rules for selecting materials and designing hinges. Torque was shown to increase with SMP thickness, resistive circuit width, and supplied electrical current. This technique was shown to be capable of complex geometries, as well as locking assemblies with sequential folds. Its functionality and low cost make it an ideal basis for a new type of printable manufacturing based on two-dimensional fabrication techniques.

Self-folding origami: shape memory composites activated by uniform heating

Self-folding is an approach used frequently in nature for the efficient fabrication of structures, but is seldom used in engineered systems. Here, self-folding origami are presented, which consist of shape memory composites that are activated with uniform heating in an oven. These composites are rapidly fabricated using inexpensive materials and tools. The folding mechanism based on the in-plane contraction of a sheet of shape memory polymer is modeled, and parameters for the design of composites that self-fold into target shapes are characterized. Four self-folding shapes are demonstrated: a cube, an icosahedron, a flower, and a Miura pattern; each of which is activated in an oven in less than 4 min. Self-sealing is also investigated using hot melt adhesive, and the resulting structures are found to bear up to twice the load of unsealed structures.

Robot self-assembly by folding: A printed inchworm robot

Printing and folding are fast and inexpensive methods for prototyping complex machines. Self-assembly of the folding step would expand the possibilities of this method to include applications where external manipulation is costly, such as micro-assembly, mass production, and space applications. This paper presents a method for self-folding of printed robots from two-dimensional materials based on shape memory polymers actuated by joule heating using embedded circuits. This method was shown to be capable of sequential folding, angle-controlled folds, slot-and-tab assembly, and mountain and valley folds. An inchworm robot was designed to demonstrate the merits of this technique. Upon the application of sufficient current, the robot was able to fold into its functional form with fold angle deviations within six degrees. This printed robot demonstrated locomotion at a speed of two millimeters per second.

Design, fabrication, and modeling of the split actuator microrobotic bee

The split actuator microrobotic bee is the first flight-capable, insect-scale flapping-wing micro air vehicle that uses “split-cycle” constant-period frequency modulation to control body forces and torques. Building this vehicle is an intricate challenge, but by leveraging a maturing fabrication technology for microscale devices, we have developed a solution to tackle the design and fabrication difficulties. We show that the design is able to independently modulate the motions of both wings and produce roll, pitch, and yaw torques, as well as a peak lift force of 1.3 mN, in a 70mg package.

Self-assembling sensors for printable machines.

Self-assembled structures and machines can be made using origami-inspired manufacturing methods. In particular, self-folding of two-dimensional materials using shape memory polymers and embedded electrical circuits has been utilized to build robots and structures in an inexpensive and rapid manner. In order to build increasingly complex and functional self-folding machines, however, methods for interaction with the environment are necessary. This paper presents and characterizes three types of self-folding sensors: a mechanical switch, a capacitive contact sensor, and a velocity sensor. We utilize specialized fold patterns to create cyclic mechanical linkages as well as additional composite layers such as magnetic sheets to build these sensors. We demonstrate the integration of two of these sensors, the switch and the contact sensor, into a lamp that can self-fold and immediately begin responding to its surroundings.

Associating the mesoscale fiber organization of the tongue with local strain rate during swallowing

The tongue is an intricately configured muscular organ that undergoes a stereotypical set of deformations during the course of normal human swallowing. In order to demonstrate quantitatively the relationship between 3D aligned lingual fiber organization and mechanics during swallowing, the tissues myoarchitecture and strain rate were imaged before and during the propulsive phase of a 3.0ml water bolus swallow. Mesoscale fiber organization was imaged with high-resolution diffusion tensor imaging (DTI) and multi-voxel myofiber tracts generated along maximum diffusion vectors. Tissue compression/expansion was obtained via lingual pressure-gated phase-contrast (PC) MRI, a method which determines local strain rate as a function of the phase shift occurring along an applied gradient vector. The co-alignment of myofiber tract direction and the localized principal strain rate vectors was obtained by translating the strain rate tensor into the reference frame with the primary axis parallel to the maximum diffusion vector using Mohrs circle, resulting in the generation of fiber-aligned strain rate (FASR). DTI tractography displayed the complete fiber anatomy of the tongue, consisting of a core region of orthogonally aligned fibers encased within a longitudinal sheath, which merge with the externally connected styloglossus, hyoglossus, and genioglossus fibers. FASR images obtained in the mid-sagittal plane demonstrated that bolus propulsion was associated with prominent compressive strain aligned with the genioglossus muscle combined with expansive strain aligned with the verticalis and geniohyoid muscles. These data demonstrate that lingual deformation during swallowing involves complex interactions involving intrinsic and extrinsic muscles, whose contractility is directed by the alignment of mesoscale fiber tracts.

Self-folding with shape memory composites at the millimeter scale

Self-folding is an effective method for creating 3D shapes from flat sheets. In particular, shape memory composites—laminates containing shape memory polymers—have been used to self-fold complex structures and machines. To date, however, these composites have been limited to feature sizes larger than one centimeter. We present a new shape memory composite capable of folding millimeter-scale features. This technique can be activated by a global heat source for simultaneous folding, or by resistive heaters for sequential folding. It is capable of feature sizes ranging from 0.5 to 40 mm, and is compatible with multiple laminate compositions. We demonstrate the ability to produce complex structures and mechanisms by building two self-folding pieces: a model ship and a model bumblebee.

Self-folding and self-actuating robots: A pneumatic approach

Self-assembling robots can be transported and deployed inexpensively and autonomously in remote and dangerous environments. In this paper, we introduce a novel self-assembling method with a planar pneumatic system. Inflation of pouches translate into shape changes, turning a sheet of composite material into a complex robotic structure. This new method enables a flat origami-based robotic structure to self-fold to desired angles with pressure control. It allows a static joint to become dynamic, self-actuate to reconfigure itself after initial folding. Finally, the folded robot can unfold itself at the end of a robotic application. We believe this new pneumatic approach provides an important toolkit to build more powerful and capable self-assembling robots.

A passive, origami-inspired, continuously variable transmission

Transmissions play a vital role in machines by transforming the torque and speed of a motor into a desired output. They are often necessary for operating a motor at peak efficiency or power. The majority of variable transmissions are mechanically complex, large, and expensive, which limits scalability and is often cost prohibitive. As an alternative, we propose an origami-wheel design that is capable of varying its own transmission ratio between motor torque and ground reaction force, effectively creating a passive, continuously variable transmission. The wheel responds to an increase in torque by reducing its radius through the spring-like properties of the origami structure, increasing the force applied by the wheel to the ground. We demonstrate that the wheel is able to match the speed of a 55 mm fixed-radius wheel when unloaded, and can also tow loads as high as a 25 mm wheel without stalling. This design could be used to provide smaller, cheaper robots with an effective means to vary their output while maintaining motor efficiency.