Design of Passive Dynamic Walking Robots for Additive Manufacture

Ongoing research in the direction of printable, non-assembly mechatronic systems give rise to the need for multi-material printing, including electronics. However, there are robotic systems that do not use electronic components and still exhibit complex dynamic behavior. Such passive dynamic systems have the potential to save energy and component cost in the field of robotics compared to actuated systems. Ongoing research in computational design synthesis of passive dynamic systems aims at automatically generating robotic configurations based on a given task. However, an automated design-to-fabrication process also requires a flexible fabrication method. Towards the goal of printing functional, non-assembly passive dynamic robots using Fused Deposition Modeling (FDM), this paper explores designing and fabricating passive walking robots and all necessary components using single material FDM. Two configurations of passive dynamic walkers are re-designed and fabricated in this paper. For one of them all components are printed in one job and only little assembly after printing is needed. However, the gait cycle of the second configuration is much more sensitive to small parametric changes and therefore more flexible prototyping is needed in order to allow adjusting of the robot after printing. Moreover, FDM printed robotic joints with sufficient smoothness and axial stiffness are required and a variety of different joint assemblies are designed and tested for the robot prototypes. Even though the most stable gait for the second robot is achieved using a metal bearing instead of the FDM printed ones, this is not necessary for the first robot example. The approach to prototyping with FDM presented in this paper allows achieving functionality through design iteration without incurring significant cost. To arrive at feasible solutions, a modular design approach allows to combine different joints, legs, feet and balancing weights and the connection points of the different elements are adjustable after printing, which makes it possible to shift the center of gravity and other variables of the robot.