Muscle-inspired magnetic actuators that push, pull, crawl, and grasp

TL;DR

This paper introduces muscle-inspired magnetic actuators made via laser powder bed fusion, enabling soft robots to perform complex movements like crawling, grasping, and lifting with remote magnetic control.

Contribution

It presents a novel additive manufacturing process to create programmable, multifunctional magnetic composites with tunable stiffness and magnetization for soft robotic applications.

Findings

Actuators can lift 50 g, 32 times their weight, under magnetic fields.

The system achieves 100% locomotion success on textured surfaces.

Reversible grasping and releasing of objects demonstrated.

Abstract

Functional magnetic composites capable of large deformation, load bearing, and multifunctional motion are essential for next-generation adaptive soft robots. Here, we present muscle-inspired magnetic actuators (MMA), additively manufactured from a thermoplastic/permanent magnet polyurethane/Nd2Fe14B (TPU/MQP-S) composite using laser powder bed fusion (LPBF). By tuning the laser-energy scale between 1.0 and 3.0, both mechanical stiffness and magnetic response are precisely controlled: the tensile strength increases from 0.28 to 0.99 MPa while maintaining 30-45% elongation at break. This process enables the creation of 0.5 mm-thick flexural hinges, which reversibly bend and fold under moderate magnetic fields without damage. Two actuator types are reported showing the system versatility. The elongated actuator with self-weight of 1.57 g, magnetized in its contracted state, achieves linear contraction under a 500 mT field, lifting 50 g (32x its own weight) and sustaining performance over at least 50 cycles. Equipped with anisotropic frictional feet, it supports movement of a magnetic crawling robot that achieves up to 100% locomotion success on textured substrates. The expandable actuator exhibits reversible opening and closing under a 300 mT field, reliably grasping and releasing different objects, including soft berries and rigid 3D printed geometries. It can also anchor in a tube while holding suspended 50 g loads. This work demonstrates a LPBF-based strategy to program both stiffness and magnetization within a single material system, enabling remotely driven, reconfigurable, and fatigue-resistant soft actuators. The approach opens new possibilities for force controlled, multifunctional magnetic soft robots for adaptive gripping, locomotion, and minimally invasive manipulation of biomedical tools.