Name: design and fabrication of an elastomeric unit for soft modular robots in minimally invasive surgery
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This work was supported by the EC within the framework of the STIFF-FLOP FP7-ICT-2011.2.1 European Project (#287728).

Note: This protocol describes the fabrication phases of a single module, which includes the fluidic chambers, stiffening channel, actuation pipelines and external sheath. The following procedure has to be executed under a fume hood and wearing lab coat and gloves for safety reasons. As previously mentioned, the fabrication process of the elastomeric unit is based on the sequential use of molds designed with CAD software. They are composed of the 13 pieces shown in Figure 2 and listed in Table 1.
1. Preparation of the Silicone
<ol>
	<li>Weigh 12 g of part A and 12 g of part B in the same plastic glass or Petri dish and mix them together, stirring. 
	Note: Material proportions can vary depending on the specific silicone used, in this case it consists of two parts: part A (the base) and part B (the catalyst). They are used in proportion 1A:1B in weight.</li>
	<li>Place the glass containing the mixed silicone materials in a degasser machine at 1 bar vacuum pressure. Keep the glass under vacuum until all the bubbles are removed from the silicone material. For the employed silicone the degassing process takes about 10 min. Once the materials are completely free from the presence of bubbles, restore the atmospheric pressure into the machine and use the silicone.</li>
</ol>
2. Fabrication of the Siliconic Module
<ol>
	<li>Assembly of the mold.
	<ol>
		<li>Insert the stiffening cylinder and the top of the chambers into cap_A (Figure 3a).</li>
		<li>Close the shells around the second layer of cap_A.</li>
	</ol>
	</li>
	<li>First silicone casting.
	<ol>
		<li>Pour the silicone inside the assembled mold up to the edge of the shells (Figure 3b).</li>
		<li>Place the mold in an oven at 60 &#176;C for about 30 min.</li>
	</ol>
	</li>
	<li>Rearrangement of the mold.
	<ol>
		<li>Remove the external shells and cap_A (Figure 3c).</li>
		<li>Insert the cylinders from the bases of the chambers and the stiffening cylinder inside cap_B (Figure 3d).</li>
		<li>Close the shells again around the module, sliding them of 10 mm upward in order to have a gap of 10 mm between the top surface of the module and the edges of the shells (Figure 3e).</li>
	</ol>
	</li>
	<li>Second silicone casting.
	<ol>
		<li>Pour the silicone inside the rearranged mold up to the edge of the shells on the top side (i.e. also up to the stiffening cylinder) (Figure 3f).</li>
		<li>Put the mold into an oven at 60 &#176;C for about 30 min.</li>
		<li>Remove the external shells, cap_B and the chambers (except the stiffening cylinder) (Figure 3g).</li>
	</ol>
	</li>
</ol>
3. Insertion of the Tubes
<ol>
	<li>Cut 3 tubes to the same desired length (300 mm for example).</li>
	<li>Put siliconic glue around one end of each tube for 10 mm, without obstructing the tubes.</li>
	<li>Insert the tubes inside the 2 mm dedicated channels in the siliconic unit (Figure 3h).</li>
	<li>Allow a curing time of 12 min at room temperature or put the module inside an oven at a higher temperature (50&#176; - 60&#176;) to speed up the drying process.</li>
</ol>
4. Fabrication of the Crimped Braided Sheath
<ol>
	<li>Cut 700 mm of an expandable braided sheath (about 15 times the height of the module).</li>
	<li>Insert a metallic cylinder of 30 mm in diameter and 250 mm in length inside the sheath.</li>
	<li>Push down and force the sheath by sliding over the cylinder, in order to create crimps.</li>
	<li>Mechanically fix the sheath in place with a clamp and heat with a heating gun at 350 &#176;C for 2-3 min until a permanent deformation is obtained.</li>
	<li>Let the sheath cool down and remove the internal cylinder.</li>
</ol>
5. Integration of the External Sheath
<ol>
	<li>Pass the tubes through the holes of cap_C.</li>
	<li>Pour 3 g of silicone into cap_C.</li>
	<li>Clamp cap_C to a support that is higher than the work plane.</li>
	<li>Insert the bottom side of the module previously fabricated into cap_C.</li>
	<li>Slide the crimped sheath around the module.</li>
	<li>Push the first crimps of the sheath inside cap_C and dip them into the freshly poured silicone (Figure 3i).</li>
	<li>Put the mold into an oven at 60 &#176;C for about 20 min.</li>
	<li>Repeat the same procedure from point 5.1-5.6 to fix the sheath at the top side, using cap_D (Figure 3j).</li>
	<li>Remove cap_C and cap_D.</li>
	<li>Remove the central cylinder (Figure 3k).</li>
</ol>
6. Fabrication of the Granular Jamming Membrane
<ol>
	<li>Pour 5 g of liquid latex into a plastic glass.</li>
	<li>Immerse the cylinder for the membrane (last piece shown in Figure 2) inside the liquid latex until the surface is completely covered.</li>
	<li>Let it dry under a hood for 20 min.</li>
	<li>Repeat points 6.2 and 6.3.</li>
	<li>Remove the membrane from the mold.</li>
</ol>
7. Insertion of the Granular Jamming Membrane
<ol>
	<li>Cut a tube (2 mm in diameter) to the desired length (300 mm for example).</li>
	<li>Cut a squared piece of about 100 mm2 of nylon tissue and close one end of the tube with this tissue using a plastic paraffin film or superglue.</li>
	<li>Weigh 4 g of coffee powder and fill the membrane.</li>
	<li>Insert the tube (the end with the filter) inside the filled membrane and fix it around the tube using a plastic paraffin film.</li>
	<li>Apply a vacuum on the other side of the tube (the membrane becomes stiffer).</li>
	<li>Insert the membrane inside the empty central channel of the siliconic module (Figure 3l).</li>
	<li>Glue the ends of the stiffening membrane to the silicone module.</li>
	<li>Close the rings around the top side of the module (Figure 3m).</li>
	<li>Pour 2 g of silicone into the rings in order to level the surface.</li>
	<li>Let the silicone dry under hood or in an oven at 60&#176;.</li>
	<li>Remove the rings.</li>
	<li>Repeat from points 7.8 to 7.11 for the bottom side (Figure 3n).</li>
</ol>

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The authors have nothing to disclose.

The technique described in this protocol enables the fabrication of a pneumatically actuated soft unit usable for modular compliant structures. Thanks to the design of the molds and their simple assembly, it is possible to fabricate one complete module in about 4 hours with 7 main steps. The process of fabrication involves specific materials, which are easily available, and work should be carried out under a fume hood. An external set up including air valves, air compressor and vacuum pump is necessary to activate the module motion and stiffening. 
For the fabrication of the soft unit, several elastomeric materials were mechanically tested in order to choose the most suitable for the specific application. Silicone was selected for its high flexibility, low hysteresis, and easy molding. 
The fabrication process is based on simple steps, however various critical aspects should be discussed. The fabrication of the crimped braided sheath, reported in Section 4 of the protocol, starts from a commercial braided sheath in polyester with an internal diameter of 32 mm. The dimensions of the metallic cylinder, used for crimping, have to ensure the right development of the crimps, the necessary space to insert the module (inner diameter) and the sufficient distance between the crimps. These features enable the module to work correctly when the chambers are inflated: the sheath has the function to limit the radial expansion of the silicone when the chambers are inflated, avoiding the &#8220;balloon effect&#8221; of the chambers. Close crimps improve the expansion of the silicone along the motion direction optimizing the bending and the elongation movements. In addition, particular care is needed when heating the sheath in order to prevent overheating, which can degrade the material. 
Considering the fabrication and the insertion of the granular jamming membrane (step 6 in the protocol), the filter on the tip of the vacuum tube is necessary to prevent dispersion of the granular material inside the fluidic system. At the moment, the filter consists of a nylon tissue. However, a miniaturized commercial filter could make the vacuum activation safer. The current membrane used for the granular jamming is made of latex. This material ensures a good level of stiffness when the vacuum is applied. However, this requires more attention: the latex inhibits the polymerization of platinum-catalyzed silicone on the top and bottom of the module. The siliconic glue, mentioned in Section 7.7, fixes the membrane and also isolates the latex from the silicone at the extremity of the module, thus the final polymerizations are guaranteed. 
Multiple units can be integrated in order to obtain a multi-module manipulator. Preliminary research demonstrates the possibility of connecting three modules20, 21 with a functionally modular architecture where each module replicates the same functionalities. However this integration is limited to a maximum of 3 or 4 modules, due to the method of passing the tubes inside the chambers. This method reduces the available space, thus limiting the multi-module approach to a low number of modules.
Future work will focus on integrating on-board valves, thus enhancing the modularity. The same fabrication technique can be used to produce miniaturized modules (quantities should scale accordingly), however the performance decay has not yet been evaluated. The list of materials used, could be further modified to meet more stringent biocompatibility requirements.

Recent trends in the medical field are pushing for a reduction in the invasiveness of surgical operations. Minimally Invasive Surgery (MIS) has been successfully improved in the last few years for abdominal operations. MIS procedures are based on the use of tools introduced through four or five access points (trocars) placed on the abdominal wall. In order to reduce the number of trocars, the instruments can be inserted by Single Port Laparoscopy (SPL) or Natural Orifice Translumenal Endoscopic surgery (NOTES)1. These procedures prevent external visible scars, but increase the difficulty for the clinicians in executing the surgery. This limitation is mainly due to the reduced points of access and to the rigid and semi-rigid nature of the instruments, which are not able to avoid or pass around organs2, 3. Dexterity and motility can be improved using articulated and hyper-redundant robots which can cover a wider and more complex workspace, thus enabling a specific target in the body to be reached more easily4, 5, 6 and to work as retraction systems when necessary7. A flexible manipulator can improve tissue compliance, thus making contact safer than by traditional tools.
However, these manipulators often lack stability when the target is reached and generally they cannot control the contact with the surrounding tissues8, 9. Studies on biological structures, such as the octopus arm10 and the elephant trunk11, have recently inspired the design of flexible, deformable and compliant manipulators with a redundant number of Degrees of Freedom (DoFs) and controllable stiffness12. These kinds of devices utilize passive springs, smart materials, pneumatic elements, or tendons13, 14, 15. Generally, manipulators fabricated with soft and flexible materials do not guarantee the generation of high forces.
The STIFF-FLOP (STIFFness controllable Flexible and Learnable manipulator for surgical OPerations) manipulator has been recently presented as a novel surgical device for NOTES and SPL inspired by the octopus&#8217;s capabilities. In order to overcome the limitations of previous soft manipulators, it has a soft body as well as high dexterity, high force and controllable stiffness16.
The architecture of the manipulator is based on a modular approach: multiple units, with the same structure and functionalities, are integrated together. The single unit is shown in Figure 1. It is based on an elastomeric cylinder obtained by a multiphase fabrication. The assembly steps of the mold components and the casting processes enable three empty chambers (for fluidic actuation) and one hollow central channel17 (for housing a granular jamming-based mechanism18) to be embedded. The chambers are placed at 120&#176;, so that their combined inflation produces omnidirectional motion and elongation. In addition an external braided sheath is placed externally to limit the outward radial expansion of the fluidic chambers when pressurized, thus optimizing the effect of the chamber actuation in the module motion (bending and elongation).
The central channel houses a cylindrical device composed of an external membrane filled with granular material. When a vacuum pressure is applied, it changes its elastic properties causing a stiffening which affects the entire module&#8217;s properties.
Motion and stiffness performances are controlled by an external setup including an air compressor and three pressure valves for actuating the chambers and one vacuum pump for activating the vacuum in the stiffening channel. An intuitive user interface allows control of actuation and vacuum pressures inside the module.
This paper details the fabrication process of the single module of this manipulator and reports the most significant results on basic motion capabilities. Considering the modular nature of the device, the assessment of the fabrication and performance of just one single module also enables the results to be extended and to predict the basic behavior of a multi-module manipulator integrating two or more modules.

<table><tbody><tr><td>Ecoflex 00-50 Trial Kit</td><td>SmoothOn</td><td></td><td>Used for the fabrication of the soft unit, combining equal amounts of liquid parts A (the base) and B (the catalyst)</td></tr><tr><td>Latex</td><td>Antichit&amp;agrave; Belsito</td><td></td><td>Used for the fabrication of the granular jamming membrane</td></tr><tr><td>Peroxide-Cured Silicone Tubing</td><td>Cole Parmer</td><td>T-06411-59</td><td>Used for actuating the chambers and applying vacuum</td></tr><tr><td>PET expandable braided sleeving</td><td>RS</td><td>408-249</td><td>Used for the fabrication of the external braided sheath</td></tr><tr><td>Silicone Rubber</td><td>Momentive</td><td>127374</td><td>Used to fix the actuation tubes to the module</td></tr><tr><td>Parafilm</td><td>Cole Parmer</td><td>EW-06720-40</td><td>Used to fix the latex membrane to the vacuum tube</td></tr><tr><td>Fume hood Secuflow</td><td>Groupe Waldner</td><td></td><td>Working space</td></tr><tr><td>Precision scale</td><td>KERN EW</td><td></td><td>Used to weight silicone, latex and coffee powder</td></tr><tr><td>Oven/degasser</td><td>Heraeus</td><td></td><td>Used to degass the silicone and reduce its cure time</td></tr><tr><td>Vacuum pump</td><td>DVP Vacuum Technology</td><td></td><td>Used to apply vacuum to the latex membrane</td></tr></tbody></table>

design and fabrication of an elastomeric unit for soft modular robots in minimally invasive surgery

In recent years, soft robotics technologies have aroused increasing interest in the medical field due to their intrinsically safe interaction in unstructured environments. At the same time, new procedures and techniques have been developed to reduce the invasiveness of surgical operations. Minimally Invasive Surgery (MIS) has been successfully employed for abdominal interventions, however standard MIS procedures are mainly based on rigid or semi-rigid tools that limit the dexterity of the clinician. This paper presents a soft and high dexterous manipulator for MIS. The manipulator was inspired by the biological capabilities of the octopus arm, and is designed with a modular approach. Each module presents the same functional characteristics, thus achieving high dexterity and versatility when more modules are integrated. The paper details the design, fabrication process and the materials necessary for the development of a single unit, which is fabricated by casting silicone inside specific molds. The result consists in an elastomeric cylinder including three flexible pneumatic actuators that enable elongation and omni-directional bending of the unit. An external braided sheath improves the motion of the module. In the center of each module a granular jamming-based mechanism varies the stiffness of the structure during the tasks. Tests demonstrate that the module is able to bend up to 120&#176; and to elongate up to 66% of the initial length. The module generates a maximum force of 47 N, and its stiffness can increase up to 36%.

The various phases of the fabrication, described in the Protocol, are illustrated in Figure 3.
In order to evaluate the effectiveness of the technique and the outcomes of the final prototype, the module was tested in different working conditions. An external setup allows control of both the actuation and stiffness of the module. It includes an air compressor that activates three valves. They are connected to the siliconic tubes integrated in the chambers and allow their pressurization. A vacuum pump is connected to the tube integrated in the granular jamming membrane for the module stiffness control. Valves and vacuum pump are connected to an electronic board which is linked with an intuitive user interface allowing to set the values of the actuation pressure and the vacuum level.
To analyze the bending (Figure 3) and elongation (Figure 5) performance, the module was fixed at the base and the chambers were actuated with specific air pressures. Each position of the module was acquired by optic and magnetic sensors. For the evaluation of the force (Figure 6) and stiffness (Figure 7), a load cell moved by a robot arm allowed to measure the module&#8217;s capabilities in different directions.
Bending tests (Figure 4) assess the active omnidirectional capability of the module. In case of 1-chamber bending, only one chamber has been actuated increasing the pressure inside, while for 2-chamber bending, two chambers have been simultaneously pressurized with the same pressure. The bending angle, which is the angle between the baseline and the tip line of the module (see insets in Figure 4), has been calculated for each position of the module, corresponding to the pressure values. The module is able to bend up to 120&#176; in the case of 1-chamber bending, and up to 80&#176; for 2-chamber bending. In both cases, a significant bending starts when the chambers are inflated by about 0.3 bar (all the reported pressure values are related to atmospheric pressure). The plot in Figure 4 highlights that the slope of the curve increases in correspondence of this value. This represents the point where the initial lateral expansion of the silicone is hindered by the external sheath, and the bending of the module is facilitated. From the 0.55 bar pressure, the curve is approximately constant because the sheath reaches its maximum elongation capability, the pressurized chambers have stretched out completely the available sheath and thus the longitudinal expansion of the silicone is limited to a constant value that corresponds to the maximum bending angle.
When all three chambers are simultaneously actuated with the same pressure, the module elongates, as shown in Figure 5. Starting from the length of 50 mm, the module reaches 83.3 mm, which corresponds to an elongation of about 66%. Again, the external sheath starts to show its effect at around 0.3 bar, where there is a sudden increase in elongation capability. No plateau is present at high pressures because during elongation the sheath does not reach it maximum elongation.
The module is able to generate forces from 24.1 N, when one chamber is actuated, up to 47.1 N, when three chambers are inflated (Figure 6).
The activation of 1 bar vacuum pressure (absolute) in the stiffening channel shows an increase in stiffness of the module (Figure 7) of 36% at rest conditions, 19.6%, 12.4% and 17.2% at 90&#176; bending in y, x and z directions respectively.
The presented protocol creates a single soft unit and, with various easy modifications, the same procedure enables the modules to be fabricated in order to create a multi-module manipulator. A possible solution for the manipulator is to integrate two or more modules where the pneumatic actuation is supplied in the modules by pipelines. The actuation tubes directly actuate the first module and other pipes can pass through the chambers of this module to pressurize the chambers of the next module, as demonstrated in preliminary works on module integration20, 21. In this case, the pieces of mold are the same except for the chambers that have two cylinders, one at the top and one at the bottom, for inserting and passing tubes.
<img alt="Figure 1" src="/files/ftp_upload/53118/53118fig1.jpg" /> 
Figure 1. Concept of the manipulator and CAD of the module. The manipulator is based on a multi-module approach. The single unit is constituted by a soft cylinder embedding three fluidic actuators, one central channel housing the granular jamming, three pipes to supply the pressure and an external braided sheath to improve module motion.
<img alt="Figure 2" src="/files/ftp_upload/53118/53118fig2.jpg" /> 
Figure 2. Mold components for the fabrication process. 13 pieces are overall used to assemble molds into which the silicone is poured and to fabricate custom latex membrane.
<img alt="Figure 3" src="/files/ftp_upload/53118/53118fig3.jpg" /> 
Figure 3. CAD of the fabrication phases. Insertion of the chambers and the stiffening cylinder into cap_A (a), first silicone casting (b), removal of shells and cap_C (c), introduction of cap_B (d), reposition of the shells (e), second silicone casting (f), removal of shells, cap_B and chambers (g), insertion of the tubes (h), insertion of cap_C and sheath for its fixing on the bottom side (i), insertion of cap_D and sheath for its fixing on the top side (j), removal of cap_D and stiffening cylinder (k), insertion of the granular jamming membrane (l), closing of the semi-rings around the module (m), final module (n).
<img alt="Figure 4" src="/files/ftp_upload/53118/53118fig4.jpg" /> 
Figure 4. Bending test. Behavior of the module when one chamber is actuated (blue line) and when two chambers are actuated (pink line). Bending angle is indicated on the module in the insets. The range in pressure used for actuating the module goes from 0 bar to 0.65 bar with steps of 0.05. For each position of the module, the bending angle was calculated. This figure has been cited from[19].
<img alt="Figure 5" src="/files/ftp_upload/53118/53118fig5.jpg" /> 
Figure 5. Elongation test. Behavior of the module during the elongation. All three chambers are simultaneously actuated with the same pressure. The pressure range goes from 0 bar to 0.65 bar. For each position the elongation was calculated. This figure has been cited from [19].
<img alt="Figure 6" src="/files/ftp_upload/53118/53118fig6.jpg" /> 
Figure 6. Force test. Evaluation of the force in isometric conditions along x direction. A load cell was positioned on the top of the module and the force was calculated in three different cases relative to the number of actuated chambers. This figure has been cited from[19].
<img alt="Figure 7" src="/files/ftp_upload/53118/53118fig7.jpg" /> 
Figure 7. Stiffness test. Evaluation of the stiffness variation in four different configurations when the same chamber is actuated. Different displacements were imposed on the tip of the module using a 6 DoF robot. The stiffness was calculated in the base condition of the module (a) and at 90&#176; bending along y, x and z directions (b, c, d). This figure has been modified from[19]. 
&#160;
<table border="0" cellpadding="0" cellspacing="0" style="width:533px;" width="533">
	<colgroup>
		<col />
		<col />
		<col />
	</colgroup>
	<tbody>
		<tr height="20">
			<td height="20" style="height:20px;width:160px;">Mold Component</td>
			<td style="width:59px;">Number</td>
			<td style="width:315px;">Description</td>
		</tr>
		<tr height="120">
			<td height="120" style="height:120px;">Shells</td>
			<td>2</td>
			<td style="width:315px;">These have a semi-cylindrical shape, are 40 mm in height, with an internal radius of 12.5 mm and external radius of 14.5 mm. When closed, they form a cylinder that represents the shape of the siliconic unit. The shells are fabricated in polyoxymethylene.</td>
		</tr>
		<tr height="180">
			<td height="180" style="height:180px;">Chambers</td>
			<td>3</td>
			<td style="width:315px;">These chambers represent the negative of the actuation chambers. They have a semi-cylindrical full shape with rounded edges, are 30 mm in height with a 4 mm radius. To facilitate the introduction of the actuation pipelines, at the base of each chamber there is a cylinder with a diameter of 1.5 mm and a length of 13 mm. The chambers are fabricated with a 3D printer machine.</td>
		</tr>
		<tr height="85">
			<td height="85" style="height:85px;width:160px;">Stiffening Cylinder (for the granular jamming mechanism</td>
			<td>1</td>
			<td style="width:315px;">This is the negative of the stiffening channel. It is 56 mm in height and 8 mm in diameter. It is fabricated in aluminum in order to facilitate its removal from the center of the siliconic cylinder.</td>
		</tr>
		<tr height="200">
			<td height="200" style="height:200px;">cap_A</td>
			<td>1</td>
			<td style="width:315px;">This is a support piece used to fix and align the pieces listed above. It is a disk measuring 10 mm in height, with a diameter of 29 mm for the first 7 mm of height, and 25 mm for the other 3 mm where the external shells close. The top shapes of the chambers are designed inside the second layer, placed at 120&#176;, with a depth of 3 mm in order to insert the top chambers. In the center of the cap, a hole of 8 mm in diameter houses the cylinder of the stiffening channel.&#160;&#160;</td>
		</tr>
		<tr height="80">
			<td height="80" style="height:80px;">cap_B</td>
			<td>1</td>
			<td style="width:315px;">This support piece is similar to the cap_A, just differs for the second layer which has three holes for the introduction of the cylinders designed at the base of the chambers.</td>
		</tr>
		<tr height="140">
			<td height="140" style="height:140px;">cap_C and cap_D</td>
			<td>1 each</td>
			<td style="width:315px;">These supports enable the sheath to be fixed to the module. They have an internal diameter of 35 mm and a central hole of 8 mm in diameter for inserting the stiffening cylinder. Cap_C differs from cap_D because it has 3 holes of 2 mm in diameter to enable the pipes to be inserted.&#160;</td>
		</tr>
		<tr height="80">
			<td height="80" style="height:80px;">Semi-rings</td>
			<td>2</td>
			<td style="width:315px;">They have an internal diameter of 30 mm and a height of 10 mm. They are made of aluminum. They are used in the last phase of the fabrication to close the module definitively.&#160;</td>
		</tr>
		<tr height="160">
			<td height="160" style="height:160px;">Cylinder for Membrane</td>
			<td>1</td>
			<td style="width:315px;">It is used for the fabrication of a custom membrane for the granular jamming mechanism. It is 50 mm in height and 15 mm in diameter, and has rounded extremities to obtain a convenient shape for the membrane to be introduced into the module. At the base, one thin cylindrical part fixes the mold onto a support during the membrane fabrication.</td>
		</tr>
	</tbody>
</table>
Table 1. Mold Components.

Watch this Scientific Journal Video about Design and Fabrication of an Elastomeric Unit for Soft Modular Robots in Minimally Invasive Surgery at JoVE.com

Design and Fabrication of an Elastomeric Unit for Soft Modular Robots in Minimally Invasive Surgery

This paper describes the design and fabrication of a soft unit for surgical manipulators. The base module includes three flexible fluidic actuators to achieve omnidirectional bending and elongation, and a granular jamming-based mechanism to enable stiffness control. A complete mechanical characterization is also reported.

In recent years, soft robotics technologies have aroused increasing interest in the medical field due to their intrinsically safe interaction in ...

design-fabrication-an-elastomeric-unit-for-soft-modular-robots

Universidad San Sebastian

Research

JoVE Journal

Bioengineering

8.9K Views.  Scuola Superiore Sant'Anna. This paper describes the design and fabrication of a soft unit for surgical manipulators. The base module includes three flexible fluidic actuators to achieve omnidirectional bending and elongation, and a granular jamming-based mechanism to enable stiffness control. A complete mechanical characterization is also reported. 

Video: Design and Fabrication of an Elastomeric Unit for Soft Modular Robots in Minimally Invasive Surgery

Fabrication Process of Silicone-based Dielectric Elastomer Actuators

This contribution demonstrates the fabrication process of dielectric elastomer transducers (DETs). DETs are stretchable capacitors consisting of an elastomeric dielectric membrane sandwiched between two compliant electrodes. The large actuation strains of these transducers when used as actuators (over 300% area strain) and their soft and compliant nature has been exploited for a wide range of applications, including electrically tunable optics, haptic feedback devices, wave-energy harvesting, deformable cell-culture devices, compliant grippers, and propulsion of a bio-inspired fish-like airship. In most cases, DETs are made with a commercial proprietary acrylic elastomer and with hand-applied electrodes of carbon powder or carbon grease. This combination leads to non-reproducible and slow actuators exhibiting viscoelastic creep and a short lifetime. We present here a complete process flow for the reproducible fabrication of DETs based on thin elastomeric silicone films, including casting of thin silicone membranes, membrane release and prestretching, patterning of robust compliant electrodes, assembly and testing. The membranes are cast on flexible polyethylene terephthalate (PET) substrates coated with a water-soluble sacrificial layer for ease of release. The electrodes consist of carbon black particles dispersed into a silicone matrix and patterned using a stamping technique, which leads to precisely-defined compliant electrodes that present a high adhesion to the dielectric membrane on which they are applied.

This manuscript shows the fabrication process for the manufacture of dielectric elastomer soft actuators based on silicone membranes. The three key stages of production are presented in detail: blade casting of thin silicone membranes; pad printing of compliant electrodes; and the assembly of all the components.

This contribution demonstrates the fabrication process of dielectric elastomer transducers (DETs). DETs are stretchable capacitors consisting of an ...

Engineering

Fabrication of Soft Pneumatic Network Actuators with Oblique Chambers

Soft pneumatic network actuators have become one of the most promising actuation devices in soft robotics which benefits from their large bending deformation and low input. However, their monotonous bending motion form in two-dimensional (2-D) space keeps them away from wide applications. This paper presents a detailed fabrication method of soft pneumatic network actuators with oblique chambers, to explore their motions in three-dimensional (3-D) space. The design of oblique chambers enables actuators with tunable coupled bending and twisting capabilities, which gives them the possibility to move dexterously in flexible manipulators, to become biologically inspired robots and medical devices. The fabrication process is based on the molding method, including the silicone elastomer preparation, chamber and base parts fabrication, actuator assembly, tubing connections, checks for leaks, and actuator repair. The fabrication method guarantees the rapid manufacturing of a series of actuators with only a few modifications in the molds. The test results show the high quality of the actuators and their prominent bending and twisting capabilities. Experiments of the gripper demonstrate the advantages of the development in adapting to objects with different diameters and providing sufficient friction.

Here we present a fabrication method of soft pneumatic network actuators with oblique chambers. The actuators are capable of generating coupled bending and twisting motions, which broadens their application in soft robotics.

Soft pneumatic network actuators have become one of the most promising actuation devices in soft robotics which benefits from their large bending ...

Design and Implementation of a Bespoke Robotic Manipulator for Extra-corporeal Ultrasound

With the potential for high precision, dexterity, and repeatability, a self-tracked robotic system can be employed to assist the acquisition of real-time ultrasound. However, limited numbers of robots designed for extra-corporeal ultrasound have been successfully translated into clinical use. In this study, we aim to build a bespoke robotic manipulator for extra-corporeal ultrasound examination, which is lightweight and has a small footprint. The robot is formed by five specially shaped links and custom-made joint mechanisms for probe manipulation, to cover the necessary range of motion with redundant degrees of freedom to ensure the patient&#39;s safety. The mechanical safety is emphasized with a clutch mechanism, to limit the force applied to patients. As a result of the design, the total weight of the manipulator is less than 2 kg and the length of the manipulator is about 25 cm. The design has been implemented, and simulation, phantom, and volunteer studies have been performed, to validate the range of motion, the ability to make fine adjustments, mechanical reliability, and the safe operation of the clutch. This paper details the design and implementation of the bespoke robotic ultrasound manipulator, with the design and assembly methods illustrated. Testing results to demonstrate the design features and clinical experience of using the system are presented. It is concluded that the current proposed robotic manipulator meets the requirements as a bespoke system for extra-corporeal ultrasound examination and has great potential to be translated into clinical use.

This paper introduces the design and implementation of a bespoke robotic manipulator for extra-corporeal ultrasound examination. The system has five degrees of freedom with lightweight joints made by 3D printing and a mechanical clutch for safety management.

With the potential for high precision, dexterity, and repeatability, a self-tracked robotic system can be employed to assist the acquisition of real-time ...

Rapid Manufacturing of Thin Soft Pneumatic Actuators and Robots

This protocol describes a method for rapid manufacturing of soft pneumatic actuators and robots with an ultrathin form factor using a heat press and a laser cutter machine. The method starts with the lamination of thermoplastic polyurethane (TPU) sheets using a heat press for 10 min at the temperature of ~93 &#176;C. Next, the parameters of the laser cutter machine are optimized to produce a rectangular balloon with maximum burst pressure. Using the optimized parameters, the soft actuators are laser cut/welded three times sequentially. Next, a dispensing needle is attached to the actuator, allowing it to be inflated. The effect of geometrical parameters on the deflection of the actuator are studied systematically by varying the channel width and length. Finally, the performance of the actuator is characterized using an optical camera and a fluid dispenser. Conventional fabrication methods of soft pneumatic actuators based on silicone molding are time consuming (several hours). They also result in strong but bulky actuators, which limits the actuator&#8217;s applications. Moreover, microfabrication of thin pneumatic actuators is both time-consuming and expensive. The proposed manufacturing method in the current work resolves these issues by introducing a fast, simple, and cost-effective fabrication method of ultrathin pneumatic actuators.

This protocol describes a method for rapid manufacturing of soft pneumatic actuators and robots with a thin form factor. The fabrication method starts with lamination of thermoplastic polyurethane (TPU) sheets followed by laser cutting/welding of a two-dimensional pattern to form actuators and robots.

This protocol describes a method for rapid manufacturing of soft pneumatic actuators and robots with an ultrathin form factor using a heat press and a ...

Rod-based Fabrication of Customizable Soft Robotic Pneumatic Gripper Devices for Delicate Tissue Manipulation

Soft compliant gripping is essential in delicate surgical manipulation for minimizing the risk of tissue grip damage caused by high stress concentrations at the point of contact. It can be achieved by complementing traditional rigid grippers with soft robotic pneumatic gripper devices. This manuscript describes a rod-based approach that combined both 3D-printing and a modified soft lithography technique to fabricate the soft pneumatic gripper. In brief, the pneumatic featureless mold with chamber component is 3D-printed and the rods were used to create the pneumatic channels that connect to the chamber. This protocol eliminates the risk of channels occluding during the sealing process and the need for external air source or related control circuit. The soft gripper consists of a chamber filled with air, and one or more gripper arms with a pneumatic channel in each arm connected to the chamber. The pneumatic channel is positioned close to the outer wall to create different stiffness in the gripper arm. Upon compression of the chamber which generates pressure on the pneumatic channel, the gripper arm will bend inward to form a close grip posture because the outer wall area is more compliant. The soft gripper can be inserted into a 3D-printed handling tool with two different control modes for chamber compression: manual gripper mode with a movable piston, and robotic gripper mode with a linear actuator. The double-arm gripper with two actuatable arms was able to pick up objects of sizes up to 2 mm and yet generate lower compressive forces as compared to elastomer-coated and non-coated rigid grippers. The feasibility of having other designs, such as single-arm or hook gripper, was also demonstrated, which further highlighted the customizability of the soft gripper device, and it's potential to be used in delicate surgical manipulation to reduce the risk of tissue grip damage.

This protocol describes a rod-based approach, combining 3D-printing and soft lithography techniques for fabricating the soft gripper devices. This approach eliminates the need for an external air source by incorporating a chamber component and reduces the chance of occlusion during the sealing process, particularly for miniaturized pneumatic channels.

Soft compliant gripping is essential in delicate surgical manipulation for minimizing the risk of tissue grip damage caused by high stress concentrations ...

Fabrication of Carbon-Based Ionic Electromechanically Active Soft Actuators

Ionic electromechanically active capacitive laminates are a type of smart material that move in response to electrical stimulation. Due to the soft, compliant and biomimetic nature of this deformation, actuators made of the laminate have received increasing interest in soft robotics and (bio)medical applications. However, methods to easily fabricate the active material in large (even industrial) quantities and with a high batch-to-batch and within-batch repeatability are needed to transfer the knowledge from laboratory to industry. This protocol describes a simple, industrially scalable and reproducible method for the fabrication of ionic carbon-based electromechanically active capacitive laminates and the preparation of actuators made thereof. The inclusion of a passive and chemically inert (insoluble) middle layer (e.g., a textile-reinforced polymer network or microporous Teflon) distinguishes the method from others. The protocol is divided into five steps: membrane preparation, electrode preparation, current collector attachment, cutting and shaping, and actuation. Following the protocol results in an active material that can, for example, compliantly grasp and hold a randomly shaped object as demonstrated in the article.

This article describes a fast and simple manufacturing process of ionic electromechanically active composite materials for actuators in biomedical, biomimetic and soft robotics applications. The key fabrication steps, their importance for the actuators&#39; final properties, and some of the main characterization techniques are described in detail.

Ionic electromechanically active capacitive laminates are a type of smart material that move in response to electrical stimulation. Due to the soft, ...

Manufacturing, Control, and Performance Evaluation of a Gecko-Inspired Soft Robot

This protocol presents a method for manufacturing, control, and evaluation of the performance of a soft robot that can climb inclined flat surfaces with slopes of up to 84&#176;. The manufacturing method is valid for the fast pneunet bending actuators in general and might, therefore, be interesting for newcomers to the field of actuator manufacturing. The control of the robot is achieved by means of a pneumatic control box that can provide arbitrary pressures and can be built by only using purchased components, a laser cutter, and a soldering iron. For the walking performance of the robot, the pressure-angle calibration plays a crucial role. Therefore, a semi-automated method for the pressure-angle calibration is presented. At high inclines (&#62; 70&#176;), the robot can no longer reliably fix itself to the walking plane. Therefore, the gait pattern is modified to ensure that the feet can be fixed on the walking plane.

This protocol provides a detailed list of steps to be performed for the manufacturing, control and evaluation of the climbing performance of a gecko-inspired soft robot.

This protocol presents a method for manufacturing, control, and evaluation of the performance of a soft robot that can climb inclined flat surfaces with ...

Revolutionizing Stroke Rehabilitation with Enhanced Grasping and Finger Recovery

A Flexible Wearable Supernumerary Robotic Limb for Chronic Stroke Patients

In this study, we present a flexible wearable supernumerary robotic limb that helps chronic stroke patients with finger rehabilitation and grasping movements. The design of this innovative limb draws inspiration from bending pneumatic muscles and the unique characteristics of an elephant's trunk tip. It places a strong emphasis on crucial factors such as lightweight construction, safety, compliance, waterproofing, and achieving a high output-to-weight/pressure ratio. The proposed structure enables the robotic limb to perform both envelope and fingertip grasping. Human-robot interaction is facilitated through a flexible bending sensor, detecting the wearer's finger movements and connecting them to motion control via a threshold segmentation method. Additionally, the system is portable for versatile daily use. To validate the effectiveness of this innovation, real-world experiments involving six chronic stroke patients and three healthy volunteers were conducted. The feedback received through questionnaires indicates that the designed mechanism holds immense promise in assisting chronic stroke patients with their daily grasping activities, potentially improving their quality of life and rehabilitation outcomes.

Author Spotlight: Enhancing Grasping Abilities for Hemiplegic Patients with Flexible Robotic Limbs 

This protocol introduces a flexible wearable supernumerary robotic limb tailored to assist in finger rehabilitation for stroke patients. The design incorporates a bending sensor to facilitate seamless human-robot interaction. Validation through experiments involving both healthy volunteers and stroke patients underscores the efficacy and dependability of the proposed study.

In this study, we present a flexible wearable supernumerary robotic limb that helps chronic stroke patients with finger rehabilitation and grasping ...

Bioinspired Soft Robot with Incorporated Microelectrodes

Bioinspired soft robotic systems that mimic living organisms using engineered muscle tissue and biomaterials are revolutionizing the current biorobotics paradigm, especially in biomedical research. Recreating artificial life-like actuation dynamics is crucial for a soft-robotic system. However, the precise control and tuning of actuation behavior still represents one of the main challenges of modern soft robotic systems. This method describes a low-cost, highly scalable, and easy-to-use procedure to fabricate an electrically controllable soft robot with life-like movements that is activated and controlled by the contraction of cardiac muscle tissue on a micropatterned sting ray-like hydrogel scaffold. The use of soft photolithography methods makes it possible to successfully integrate multiple components in the soft robotic system, including micropatterned hydrogel-based scaffolds with carbon nanotubes (CNTs) embedded gelatin methacryloyl (CNT-GelMA), poly(ethylene glycol) diacrylate (PEGDA), flexible gold (Au) microelectrodes, and cardiac muscle tissue. In particular, the hydrogels alignment and micropattern are designed to mimic the muscle and cartilage structure of the sting ray. The electrically conductive CNT-GelMA hydrogel acts as a cell scaffold that improves the maturation and contraction behavior of cardiomyocytes, while the mechanically robust PEGDA hydrogel provides structural cartilage-like support to the whole soft robot. To overcome the hard and brittle nature of metal-based microelectrodes, we designed a serpentine pattern that has high flexibility and can avoid hampering the beating dynamics of cardiomyocytes. The incorporated flexible Au microelectrodes provide electrical stimulation across the soft robot, making it easier to control the contraction behavior of cardiac tissue.

A bioinspired scaffold is fabricated by a soft photolithography technique using mechanically robust and electrically conductive hydrogels. The micropatterned hydrogels provide directional cardiomyocyte cell alignment, resulting in a tailored direction of actuation. Flexible microelectrodes are also integrated into the scaffold to bring electrical controllability for a self-actuating cardiac tissue.

Bioinspired soft robotic systems that mimic living organisms using engineered muscle tissue and biomaterials are revolutionizing the current biorobotics ...

Robotics in Surgery: A Modular Robotic Platform Driven Gastric Wedge Resection

Robotic-assisted surgery has become increasingly popular since the introduction of the first robotic platform. Recently, a modular robotic system was approved for in-human use in Europe. Possible applications for this new robotic system are being explored, and standardized approaches are evolving. In lieu of this, a gastric wedge resection and the standardized setup for upper gastrointestinal procedures using this new system are presented here. This safe and feasible robotic procedure is demonstrated in a 69-year-old patient with a gastric tumor. All steps of the surgery are described in a detailed and reproducible manner. The article also details trocar positioning, arm adjustments, and required surgical instruments. Docking time amounted to 13 min, whereas the console time took 115 min. The patient was discharged after 4 days after ensuring an uneventful course. The presented method is also suitable for other surgical purposes, such as fundoplications or hiatoplasties, and ensures both generalizability and reproducibility.

Robotically assisted surgery has become highly popular in recent years. Presented here is the standard care for upper gastrointestinal procedures, including a demonstration of a robotic-assisted gastric wedge resection using a modular robotic device.

Robotic-assisted surgery has become increasingly popular since the introduction of the first robotic platform. Recently, a modular robotic system was ...