The term Poly-Limb stems from the rare birth defect syndrome, called Polymelia. Although Poly-Limbs in nature have often been nonfunctional, humans have had the fascination of functional Poly-Limbs. Science fiction has led us to believe that having Poly-Limbs leads to augmented manipulation abilities and higher work efficiency. To bring this to life however, requires a synergistic combination between robot manipulation and wearable robotics. Where traditional robots feature precision and speed in constrained environments, the emerging field of soft robotics feature robots that are inherently compliant, lightweight, and cost effective. These features highlight the applicability of soft robotic systems to design personal, collaborative, and wearable systems such as the Soft Poly-Limb.

This dissertation presents the design and development of three actuator classes, made from various soft materials, such as elastomers and fabrics. These materials are initially studied and characterized, leading to actuators capable of various motion capabilities, like bending, twisting, extending, and contracting. These actuators are modeled and optimized, using computational models, in order to achieve the desired articulation and payload capabilities. Using these soft actuators, modular integrated designs are created for functional tasks that require larger degrees of freedom. This work focuses on the development, modeling, and evaluation of these soft robot prototypes.

In the first steps to understand whether humans have the capability of collaborating with a wearable Soft Poly-Limb, multiple versions of the Soft Poly-Limb are developed for assisting daily living tasks. The system is evaluated not only for performance, but also for safety, customizability, and modularity. Efforts were also made to monitor the position and orientation of the Soft Poly-Limbs components through embedded soft sensors and first steps were taken in developing self-powered compo-nents to bring the system out into the world. This work has pushed the boundaries of developing high powered-to-weight soft manipulators that can interact side-by-side with a human user and builds the foundation upon which researchers can investigate whether the brain can support additional limbs and whether these systems can truly allow users to augment their manipulation capabilities to improve their daily lives.