Quick-cast: A method for fast and precise scalable production of fluid-driven elastomeric soft actuators

TL;DR

This paper introduces a novel manufacturing method for rapid, precise, and scalable production of complex fluid-driven elastomeric soft actuators, enabling diverse applications in soft robotics and architecture.

Contribution

It presents a new 3D moulding process adaptable for laboratory and industrial settings, producing high-quality, leak-free soft actuators with <0.2 mm precision.

Findings

Successful fabrication of multiple soft actuators with complex geometries

Demonstrated application in kinetic photovoltaic building envelopes

Achieved high precision and scalability in manufacturing process

Abstract

Fluid-driven elastomeric actuators (FEAs) are among the most popular actuators in the emerging field of soft robotics. Intrinsically compliant, with continuum of motion, large strokes, little friction, and high power-to-weight ratio, they are very similar to biological muscles, and have enabled new applications in automation, architecture, medicine, and human-robot interaction. To foster future applications of FEAs, in this paper we present a new manufacturing method for fast and precise scalable production of complex FEAs of high quality (leak-free, single-body form, with <0.2 mm precision). The method is based on 3d moulding and supports elastomers with a wide range of viscosity, pot life, and Young's modulus. We developed this process for two different settings: one in laboratory conditions for fast prototyping with 3d printed moulds and using multi-component liquid elastomers, and the other process in an industrial setting with 3d moulds micromachined in metal and applying compression moulding. We demonstrate these methods in fabrication of up to several tens of two-axis, three-chambered soft actuators, with two types of chamber walls: cylindrical and corrugated. The actuators are then applied as motion drivers in kinetic photovoltaic building envelopes.