Controlled Access. Restriction lift date: 2029-05-31
Development of a 3D-printed hybrid compliant revolute joint for modular continuum robots
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Date
2025
Authors
Wang, Zhengyao
Journal Title
Journal ISSN
Volume Title
Publisher
University College Cork
Published Version
Abstract
This thesis presents a novel hybrid compliant revolute joint (CRJ) design, developed for modular integration into a compliant continuum robot (CCR). The joint features a hybrid structure in which stiff polylactic acid (PLA) provides structural reinforcement, while flexible thermoplastic polyurethane (TPU) enables rotational compliance. These materials are spatially distributed to achieve directional stiffness control, and the joints can be monolithically manufactured using dual-material Fused Deposition Modelling (FDM) 3D printing. To support the development of this design, a systematic methodology is proposed that includes mechanical design principles, material selection, and the experimental characterisation of material properties and interfacial bonding parameters, which provides the necessary input for accurate finite element modelling in the commercial software ABAQUS. Simulation results show that the hybrid joint exhibits a higher ratio of off-axis to on-axis rotational stiffness compared to single-material joints made entirely of PLA or TPU. Furthermore, the design offers potential for programmable joint-level stiffness through local adjustment of the soft-to-stiff material ratio. When further assembled with an anti-buckling support frame, the joint becomes suitable for serial integration into a compliant-joint CCR, where the frame ensures structural stability while task-specific compliance is achieved through joint-level tuning.
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Controlled Access
Keywords
Compliant revolute joint , Compliant continuum robot , Hybrid joint design , Dual-material FDM 3D printing , Directional stiffness control , Finite element modelling (ABAQUS)
Citation
Wang, Z. 2025. Development of a 3D-printed hybrid compliant revolute joint for modular continuum robots. MRes Thesis, University College Cork.