Simplifying Foldable Robotics by Replacing Composite Hinges with Single Material Flexure Hinges

Foldable robots have gained popularity in recent years due to their versatility and portability. However, the use of composite hinges in these systems has posed challenges in terms of manufacturing complexity and cost. Historically, single material robots were very limited due to the fact that both the link and the hinge are made with the same material and striking a balance with stiffness of the link and flexibility of the hinge has been very difficult. Hinges would undergo fatigue within hundreds of cycles and show non-linear wear and physical properties. This research proposes an innovative approach to simplify foldable robotics by replacing composite hinges with single material flexure hinges. The proposed hinges are manufactured using a CO2 laser cutter and are designed to enhance performance and reduce costs over previous single-layer-hinges. A mathematical model has been developed to predict the behavior of the hinges and tune them to the desired requirements. Experimental results show that the proposed hinges offer improved flexibility and durability compared to single-layer hinges, while reducing the manufacturing cost and complexity associated with multi-layer hinges. This research contributes to the advancement of foldable robotics by offering a simplified and cost-effective solution that can foster innovation in various applications.