I’ve been playing with origami, lately. Specifically, I’ve been exploring how to simulate, model, and fold origami shapes in ways that could be automated to create useful mechanisms. The system I’ve come up with is designed to fold rip-stop nylon, which I’ve worked with a bit during my time at Makani Power and research at Super-Releaser.
After some experiments with programs designed specifically for generating origami patterns, I found I wasn’t able replicate the patterns I’d prototyped in paper. Since I wanted to start out with a paper prototype, do some bench tests, and move to CAD from there, I needed to consider other options. I also wasn’t able to convert the output into a format that would play with CAD for printing and prototyping the resulting forms. So, I fell back on my old standard: SolidWorks. If you’ve worked with me before or you’re a regular reader, you don’t get any bonus points for guessing I’d find a way to turn this into a SolidWorks project. This video was very helpful for understanding how to think about origami in a SW context.
I developed this static mixer design to streamline casting demos. Often times, a casting demo can get bogged down with portioning, mixing, and degassing, especially when you’re trying to have a group of students get hands-on time with the casting materials.
With this design, you load up degassed silicone, store the unit until needed, and then dispense mixed material out of the nozzle. If you’d like to build your own, you can find all of the source files on Thingiverse. This project was also picked up by Hack A Day.
Mark Micire (research scientist at the Intelligent Robotics Group at NASA Ames) and Yun Kyung Kim (human-robot iInteraction designer at NASA Ames) were incredibly generous in offering me an opportunity to speak with the AstroBee and Super Ball Bot groups at NASA Ames. We’ve been keeping an eye on Super Ball Bot over at Super-Releaser, particularly because of the way the teams working on it are bringing simulation and iterative prototyping together to solve the open-ended problems involved in designing a robust control system for bots that can configure themselves into nearly infinite shapes.
The talk focused on the opportunities to use compliant materials to replicate organic mechanisms, the ways Super-Releaser solves problems in soft robotics, and the way we integrate multiple disciplines into our research. Afterwards I was able to see the work of the Super Ball Bot team – developing novel compliant actuators in addition to refining the systems that power their current Ball Bot prototypes.
I was also able to see the AstroBee, which was being evaluated on the biggest granite surface plate I’ve ever seen. I got to talk with Yun about her experience as a designer integrating into a team of engineers, which is its own challenge in itself, and the goals of the AstroBee project. It’s going to serve as a platform to develop behaviors for human/machine interaction in 0g, which is a problem I’ve never even considered.
I was hired by SOLS to help out with their Adaptiv project. The idea was to showcase the procedural modeling techniques, materials, and technologies behind their printed insoles with a futuristic robotic shoe. Jordan Dialto, the industrial design lead at SOLS, approached me in my capacity as lead scientist at Super-Releaser to make a prototype soft robot shoe that could change shape and fit in response to the wearer.
The project started out with an external shell modeled by Continuum Fashion. Although the design was elegant, this posed a challenge for introducing the robotic elements and the engineered components that would stitch everything together. Since the external shell was generated in a mesh CAD program, it didn’t fit into SolidWorks’ reference frame. This meant using the mesh as a reference and generating a simplified surface to extrude the soft robot elements and retaining skeleton from. Continue reading →
I’ve been going to CCC for a while. I’ve given some talks (mostly on the lightning talk track) and have generally had a good time. More and more, though, I’ve gotten interested in gatherings that orbit big events like CCC, Maker Faire, and HOPE. Unconferences, Bsides, and nether-conferences like BarCamp are less formal than a traditional conference, and often have the kind of wiggle room for instant breakout sessions and long Q&A.
Long time no see, folks. I’ve got some great news for you. I’ve finally found a method for getting super complicated geometry locked inside of a seamless skin. It’s taken a lot of prototypes to get here, but I think the results are more than worth the effort. There are some wrinkles to iron out (which I’ll get to below) but all in all I think I’m incredibly close to rapid-fire casting working quadrupeds, ready to go in just a few short steps after popping the mold. In other good news, I’ll be dropping some files very soon which should get you your very own working quadruped using any FDM printer. All you need is a Makerbot or similar, a few hours, and some casting materials to have an exact duplicate of my most sophisticated robot to date.
This will be an update on the things I’ve learned molding quadrupeds over the last couple of months and some previews of the new robots I’ll be experimenting with in the next few weeks. To start, I’ve had the chance to run a gaggle of design experiments ranging from small changes to the particular silicone I’ve been casting, to more radical changes to how the whole plionics manufacturing process comes together.
I’ve discovered that molding complex channels of tubing can be extremely difficult, and the CAD equally infuriating. I’m discovering some automatic routing tools in SolidWorks that could streamline the process, but there might be another solution that sidesteps that whole mess entirely. It’s possible to cast around silicone tubing that’s already connecting up all the interior geometry. So, what I’d have to do to get the design working is build the cores with little fastenings for plugging in tubing and make sure all the tubes have enough clearance to get past one another. I’m anticipating the world of reality doesn’t let me off the hook that easily, but it’s a start. Continue reading →
Earlier this week I had the opportunity to show off the soft robots I’ve been developing at the National Robotics Week: Extending Human Reach event held at HUGE labs and facilitated by Honeybee Robotics. I was originally excited at the prospect of seeing the incredibly varied group, the police standing next to bomb sniffing drones, LittleBits showing off tiny circuit construction kits, Honeybee demonstrating the lab tools they designed that are currently roving around on Mars. It was a shame I didn’t have more time away from my booth to check out the tech everyone else brought, but the general crowd was so excited, so eager to chat about robots and what I was presenting, that the event was almost over before I caught my breath. Thankfully Numi was there, helping set up, answering questions, and generally being awesome.
So, now I’ve got a pile of business cards representing science minded folks to email, some new medical applications to push the next prototypes towards, and an urge to show this stuff off to the public more.
Quadrupeds. I’ve been dreaming about quadrupeds. I’ve been hunting for challenges to test my methods and improve the engineering on the whole “print and cast a soft robot” thing (I really need to come up with a name for this… “Borgatronics?”). I started with tentacles because they were easy to design, easy to test, and symmetrical.
They’ve made a lot of progress, but it’s time to turn to other designs. I’ve produced a few prototypes along one main design, and have discovered many things. I’m going to try and explain my logic behind the design and some of the major changes I intend to make in the next version. I’m also going to tell you all the myriad ways I went wrong in this design and the things I’ve done to try and make it right.
This is going to be a pretty dry technical post on the industrial design aspects of the robots I’ve been developing. I promise you entertainment and levity aplenty in the future. For now, we grump about casting flaws, mold design, and process control. Continue reading →