Design and Manufacturing of Tendon-Driven Soft Foam Robots

A design and manufacturing method is described for creating a motor tendon-actuated soft foam robot. The method uses a castable, light, and easily compressible open-cell polyurethane foam, producing a structure capable of large (70% strain) deformations while requiring low torques to operate (<0.2 N center dot m). The soft robot can change shape, by compressing and folding, allowing for complex locomotion with only two actuators. Achievable motions include forward locomotion at 13 mm/s (4.3% of body length per second), turning at 9/s, and end-over-end flipping. Hard components, such as motors, are loosely sutured into cavities after molding. This reduces unwanted stiffening of the soft body. This work is the first demonstration of a soft open-cell foam robot locomoting with motor tendon actuators. The manufacturing method is rapid (30 min per mold), inexpensive (under $3 per robot for the structural foam), and flexible, and will allow a variety of soft foam robotic devices to be produced.