Fused filament fabrication is a popular extrusion 3D printing technology because of its affordability and accessibility. However, the approach often suffers from printing errors that result in wasted time, materials and energy. Convolutional neural networks can be trained to recognise a wide spectrum of printing anomalies from image data in real time, but past work has been limited to a few defect classifications at a time. Here, we introduce a fault detection system, designed to identify a range of errors without interrupting the printing process. Real-time detection is achieved using a pre-trained image recognition and pattern recognition convolutional neural network (CNN) with two mounted cameras on the print bed and a nozzle camera. Two CNN models are developed to classify images into common 3D printing errors for the two camera systems. The nozzle camera model achieves a high validation accuracy of 97.7%. The side camera model achieves comparable performance with a validation accuracy of 97.6%. To integrate the two CNNs into one unified system, a logic-based priority framework was used to improve reliability beyond individual model accuracies by resolving conflicting predictions and leveraging complementary viewing angles from both camera types to detect a broader range of defects. The data fusion framework identifies 12 common errors and has significantly improved the robustness of error classification, in-situ and in real-time, with inference times as small as 220 milliseconds. The results demonstrate the feasibility of a robust multi-input fault detection system to advance the reliability of extrusion 3D printing.

Mechanical metamaterials are architected structures with unique functionalities, such as negative Poisson's ratio and negative stiffness, which are widely employed for absorbing energy of quasi-static and impact loads, giving improved mechanical response. Acoustic/elastic metamaterials, their dynamic counterparts, rely on frequency-dependent properties of their microstructure elements, including mass density and bulk modulus, to control the propagation of waves. Although such metamaterials introduced significant contribution for solving independently static and dynamic problems, they were facing certain resistance to their use in real-world engineering problems, mainly because of a lack of integrated systems possessing both mechanical and vibration attenuation performance. Advances in manufacturing processes and material and computational science now enable the creation of hybrid mechanical metamaterials, offering multifunctionality in terms of simultaneous static and dynamic properties, giving them the ability of controlling waves while withstanding the applied loading conditions. Exploring towards this direction, this review paper introduces the hybrid mechanical metamaterials in terms of their design process and multifunctional properties. We emphasize the still remaining challenges and how they can be potentially implemented as engineering solutions.

Enceladus, one of Saturn’s icy moons, has been a subject of intense scientific interest since the Cassini mission revealed a subsurface ocean containing salts and complex organic molecules. This ocean, buried beneath kilometers of ice, is accessible only through surface cracks at the moon’s south pole, where geysers emerge. In support of future missions searching for extraterrestrial life within our solar system, we developed a robot aimed at exploring such environments. Using Peltier elements, the robot attaches to icy surfaces by locally melting and refreezing water and detaches by re-melting the contact area. Adhesion tests based on local phase change dynamics demonstrate strong bonding, often exceeding the cohesive strength of the ice. While originally developed for planetary exploration, the underlying principle is also applicable to Earth-based operations such as exploration and rescue missions in icy environments.

Enceladus, one of Saturn’s moons, is considered one of the most promising places in the solar system to find life. The Cassini mission discovered organic-rich water plumes from Enceladus’s subsurface ocean, prompting new lander mission planning. We developed a mechanically simple ice sampling system for autonomous life detection on lander missions. The system is controlled by a single rotary actuator that samples, liquefies, and prepares ice for microscopic observations. Sample acquisition uses a novel conical boundary layer pump that delivers samples to a microfluidic disk. A digital holographic microscope detects microorganisms without mechanical focusing. The single-actuator design enables closed-loop control of velocity, position, and torque, with an operational sequence controlling fluid dynamics in a centrifugal microfluidic disk. Testing demonstrated system feasibility and effectiveness across all subsystems. Open-source software was developed for automated onboard hologram processing, including organism motility detection to assess presence of life. This single-actuator design reduces mechanical complexity for lander missions. Future work focuses on adapting the technology for terrestrial applications and achieving required technology readiness levels for space deployment.

Superelastic metamaterials have attracted significant attention recently, but achieving such functionality remains challenging due to partial superelasticity and premature fracture in additively manufactured components. To address these issues, this study investigates the premature fracture in Ni-rich NiTi metamaterials fabricated by laser powder bed fusion. A comparative analysis of two structures (Gyroid network and Diamond shell) reveals that the structural stability of bending- and stretching-dominated structures is reversed compared to typical elastic-plastic response, due to the tension-compression asymmetry of base NiTi. The premature fracture and partial superelasticity of these as-fabricated samples are attributed to low deformation ability for accommodating tensile stress. Based on these findings, a heat treatment introducing Ni₄Ti₃ precipitates was employed, successfully achieving macroscopic superelasticity in the NiTi metamaterials, with consistency between model prediction and experiments.

The offshore wind industry has grown significantly over the past decade with the increasing demand for clean energy, and over 80% of offshore wind turbines have monopile foundations. The installation of these foundations requires monopiles to penetrate several pre-installed scour protection rock layers before reaching the required penetration depth. With the increasing sizes of both monopiles and the extent of scour protection layers, various challenges arise during the monopile’s driving and self-weight penetration process, such as misalignment and early pile refusal. Lab scale testing and empirical modelling are time-consuming and normally not general enough to be applied to different scenarios. Within the Optimising Pile Installation through Scour Protection (OPIS) project, the high fidelity discrete element method (DEM) has been deployed to consider both the discrete nature and shapes of the scour protection rocks. A double-layer (armour & filter) scour protection with a sand layer underneath was simulated using the DEM. Detailed rock dynamics and the armour rocks dragging down during penetration are revealed and particle-geometry rolling friction is identified as the dominant parameter. The effects of the sand layer thickness and pile wall thickness on penetration resistance are also addressed.

Locomotion over granular terrain poses significant challenges for autonomous robotic systems, particularly in coastal regions characterized by loose, shifting sands. To optimize the locomotion on these challenging terrains, a simulation-aided design approach was used to develop a soft, shape-adapting, wheeled locomotion system. A co-simulation framework combining the discrete element method (DEM) and multibody dynamics (MBD) is employed to simulate the locomotion of a wheeled robot on varying sandy soils, covering both dry and wet sandy soil conditions. A shape-adapting wheel design is proposed, incorporating soft, inflatable elements that enable the wheel to transform between lugged and circular configurations. A discretized flexbody approach is adopted to model the interactions between the sandy soil and the soft, flexible bodies of the shape-adapting wheel design. Simulation results demonstrate improved performance of the shape-adapting wheels across a variety of sandy terrains, including slopes and obstacles. Integrating softness into the wheel improves obstacle climbing performance, while a lugged wheel configuration performs particularly well on loose, dry sandy slopes. This DEM-MBD co-simulation further enables efficient evaluation of locomotion strategies without the need for extensive physical prototyping.

Engineers frequently aim to streamline environmental factors to facilitate the effective operation of robots. However, in nature, environmental considerations play a crucial role in shaping the embodiment of organisms. To comply robots with the complexity of real-world environments, embedding similar intelligence is key. In the field of soft robotics, various approaches offer insight into how intelligence can be integrated into artificial agents. A discussed topic is the intricate relationship between the brain and the body at the core of intelligence in robots. The goal of this article is, therefore, to unravel the strategies to implement different types of intelligence currently adopted in soft robots. A classification is made by making a distinction between agents that adapt to their environment by 1) their adaptive shape, 2) their adaptive functionality, and 3) their adaptive mechanics. Additionally, the perspectives on intelligence based on their computational approach are distinguished: centralized computation, decentralized computation, or embedded computation. It is concluded that a tailored robotic design approach attuned to specific environmental demands is needed. To unlock the full potential of soft robots, a fresh perspective on embodied intelligence is described, so-called mechanical intelligence, emphasizing the robot's responsiveness to changing external conditions of a real-world environment.

In recent years, significant advancements have been made in robotics, especially with the introduction of continuum and hyper-redundant robots. These robots can be highly flexible and manoeuvrable, which makes them suitable for intricate underwater maintenance, exploration, and inspection tasks. Inspired by the motions of aquatic life, underwater snake-like robots offer a good way to accomplish subsea maintenance, exploration, and inspection activities. While many studies have been conducted on hyper-redundant, snake-like robotic arms for maintenance and inspection in land-based applications, not as much about robotics intended for marine or underwater applications has been studied. This review critically examines recent advancements in the design, actuation, and modelling of these robotic systems, categorising them into two primary families: untethered mobile robots and tethered robotic manipulators. Key insights include the identification of strengths and limitations associated with various designs and actuation strategies, such as the high manoeuvrability but limited speed of bioinspired swimming robots compared to thruster-driven designs, and the complexity versus precision trade-offs inherent in tendon-driven manipulator arms. Furthermore, the modelling techniques employed across categories are systematically analysed, as well as challenges such as the modelling of fluid–structure interactions and the need for improved real-time models for compliant and soft robots.

The growth of offshore wind farms is accelerating to meet the renewable energy target by 2030, driving the development of larger offshore wind turbines (OWTs) to boost energy capacity. To support these OWTs, large monopiles are being installed by using impact hammers, which in turn emit low-frequency underwater noise, posing challenges for traditional noise mitigation systems and increasing risks to marine life. To address this, a metamaterial-based cushion (meta-cushion) was proposed, embedding resonators to filter longitudinal waves associated with high underwater noise levels. While prior work has demonstrated the meta-cushion's noise attenuation potential, design guidelines are required for adaptation to various monopile installations. This paper introduces, for the first time, a design methodology for the meta-cushion, which based on the input parameters of the monopile system, it details the procedure for selecting the resonant elements contributing to the attenuation performance and their spatial arrangement on the cushion for enhancing mechanical performance. Such performance indicators are evaluated via finite element simulations and experimental modal analyses. The methodology concludes with a nondimensional study of the spiral resonator, which showed the best attenuation response in experiments, exploring its behavior under varying material and geometric parameters. This methodology enables the development of meta-cushions adaptable to monopile installations under any environmental conditions.

In nature, organisms such as the octopus exhibit remarkable adaptability by reconfiguring their bodies into contracting and extending segments. Translating this modularity into robotics, origami-inspired designs have proven effective in creating adaptable building blocks for modular robotic arms. The Kresling cylinder, a bistable cylindrical origami structure, exemplifies this approach by functioning as both a contracting and extending actuator. However, current actuation strategies in origami-inspired structures—such as pneumatic, mechanical, or stimuli-responsive methods—suffer from bulky actuators, slow speed, or inability to provide local actuation. Magnetically-actuated Kresling cylinders offer promising solutions for rapid and localized actuation. However, they typically rely on large external coils, limiting their use in restricted environments. To overcome this limitation, we have embedded coils directly into a modular Kresling cylinder, creating a standalone electromagnetically-actuated system. The finite element analysis was employed to understand the effect of the electromagnets' dimensions on effective contraction and extension, resulting in a weight-efficient actuator. Trends were uncovered for the design of flat, effective electromagnets for embedded electromagnetic actuation. Following these design trends, a prototype was successfully manufactured, demonstrating rapid contraction and extension in both horizontal and vertical orientation. The standalone Kresling actuator is particularly well-suited for use in dynamic, remote or restricted environments. The simple design of the manufactured prototype illustrates the potential for incorporating embodied actuation into functional soft robotic designs.

Monopiles are the dominant foundation type for offshore wind turbines, accounting for approximately 80% of the installed capacity. Installing offshore monopile foundations on seabeds susceptible to scour erosion requires monopiles to penetrate several pre-installed scour protection rock layers before securing them into the seabed. The accurate prediction of the pile penetration resistance is crucial to ensure successful monopile installations. To complement, and potentially reduce the dependence on the costly and labour-intensive experimental small-scale penetration tests, a numerical model has been developed using the Discrete Element Method (DEM) that captures the discrete nature of interactions between rocks and piles and predicts the resistance during the penetration process. The developed DEM model includes armour and filter rocks represented by multispheres and sand particles represented by spheres. A multistage calibration, verification and validation DEM modelling framework is proposed and examined with small-scale penetration tests conducted using plates and piles in a double-layer scour protection configuration. The sand material model is calibrated and verified using penetrometer tests and the rock material models are calibrated and verified using a plate penetration test. The DEM model with three verified materials predicts the penetration resistance well in small-scale pile penetration tests and proves the validity of the proposed framework. The DEM model presented in this paper facilitates the modelling in areas where traditional continuum-based numerical methods give less accurate predictions and provide insights that are difficult or nearly impossible to obtain through experimental methods.

The octopus achieves intricate arm deformations through local muscle interactions rather than centralized coordination. Inspired by this principle, this study aims to develop embodied intelligent McKibben Artificial Muscles (AMs), in which global deformation is encoded directly into their physical structure. The key design parameter explored is the braiding angle, which governs the type and magnitude of motion. By spatially varying this angle along the actuator, we demonstrate embedded capabilities for local extension and contraction within a single AM. Additionally, a mismatch in braiding angles between opposing wire sets generates a twisting motion. To implement these variations, traditional braiding techniques were adapted for localized angle control. Within a single McKibben AM, a maximum strain of +0.06 and minimum strain of −0.19 was measured. A twist angle of 100° was achieved using a 50.4° angle difference at 50 kPa actuation pressure. A final modular prototype demonstrated the integration of multiple motion modes within a single actuator body. These results highlight the potential of mechanically intelligent AMs to simplify actuation systems in soft robotics. Applications include wearable technologies such as exoskeletons and prosthetics, as well as bioinspired systems like artificial hearts or continuum robotic arms, where compact and adaptive actuation is essential.

The importance of natural environments with rugged deformable terrain from biodiversity, carbon capture, and coastal protection to economic livelihood is significant. However, the current systems available for robots to explore those ecosystems are either large, expensive and intrusive, not application focused or consist of many mechanical parts prone to failure. This study proposes a soft adaptable wheel designed and verified using a novel modelling-based approach suited for such ecosystems. The novel modelling techniques used a 3 part iterative design framework including a kinematic analysis using multi-body dynamics, structural feasibility tests using the finite element method and deformable terrain testing using the discrete element method. The final design operates as a soft fluidic actuator constructed with silicone, able to change its form depending on the task at hand. The proposed model is intended to be a more application-driven design (for rugged deformable terrain), that can more easily be integrated into robotic systems using off-the-shelf components. The simplicity and symmetry of the model can be easily scaled according to the terrain type, load requirements or application of the robotic system, ultimately reducing the time required to be used in environmental applications.

Hyper-redundant manipulators offer high dexterity and manoeuvrability in constrained environments, yet their design must integrate structural efficiency with environmental adaptability. This study presents a co-design framework for lightweight, cable-driven hyper-redundant manipulators optimised for underwater applications, such as the usage in combination with a Remotely Operated Vehicle. Building on a modular architecture of an eight-degree-of-freedom cable-driven manipulator, the methodology integrates Gaussian process regression-based stress prediction and generative design to achieve mass and size reductions, as well as a hydrodynamically efficient shape while ensuring structural integrity under extreme static loads. A 3D-printed module fabricated from Onyx, a carbon fibre-reinforced nylon, achieved near-neutral buoyancy in seawater, validated through submerged testing of a two-module prototype. An external buoyant element design was then provided for manipulators with no inherent buoyancy, accounting for printability, density mismatch between actual and theoretical density, and joint range of motion. This work advances underwater hyper-redundant robot design by combining data-driven optimisation with modular buoyancy strategies and hydrodynamic efficiency, providing a scalable method for fluid environments.

Conventional scour protection installation around monopiles for offshore wind farms involves placement of smaller filter layer rocks and larger armor layer rocks in two separate operations, requiring multiple visits of the rock dumping vessel to the site which increases costs, time spent offshore by the vessels, and consequently carbon emissions. The joint industry project Optimizing Pile Installation through Scour Protection (OPIS), established in 2023, helps reaching the target of energy transmission by streamlining the pile and scour protection installations, reducing costs and carbon emissions associated with offshore wind developments. The project investigates the technical feasibility of pile installation through coarse rock to enhance the feasibility of the operation. A series of small and medium scale laboratory experiments has been conducted, considering different scour protection designs such as single- and double-layer systems, and different rock densities (high and normal density rocks). This paper delves into the physical modelling aspects of the OPIS research project. Furthermore, this contribution elaborates on the design and intricacies of the scaled laboratory tests, providing in-depth insights into the design and implementation of laboratory setups, along with a detailed account of experimental procedures. Moreover, preliminary results and challenges encountered during the experiments are discussed, and innovative solutions devised to overcome specific challenges are highlighted.

The use of optimization procedures for designing acoustic/elastic metamaterials (A/E MMs) has gained significant interest since they enable the efficient attainment of unique functionalities often contradicting. When it comes to vibration attenuation caused by mechanical stress waves, such as impact loads, the dynamic properties of A/E MMs are optimized so that their wave-control ability is maximized. However, the mechanical performance of A/E MMs during the propagation of such waves is normally not evaluated into the design optimization stages. This may compromise not only the load-bearing capacity of MMs, but also their ability in attenuating vibrations. To prevent such effects, we propose a design strategy that incorporates the stress analysis in the early design phase of A/E MMs subjected to an impact load. The effective mass density approach is applied, from which the vibration attenuation is identified at frequency ranges where the resonator moves out-of-phase in relation to the applied excitation. Regarding to the A/E MM mechanical behavior, maximum von Mises stress is calculated through the transient analysis of a unit cell array subjected to a dynamic load. A Pareto front shows a trade-off behavior between the A/E MM functionalities. With that, we emphasize the importance of incorporating the mechanical performance into the design stage of A/E MMs for vibration attenuation of structures undergoing high impact loads, such as installation of foundations by impact hammering. This brings A/E MMs closer to real applications involving energy filtering at specific frequencies from transient loads, designed in an optimized and efficient way.

The challenge of designing real-world robots continues due to the complexities of navigating inaccessible terrains and encountering unexpected conditions. Introducing smart materials like shape memory alloys (SMAs) in the robot body can be beneficial due to their shape memory effect for actuation; however, there is no systematic way to introduce SMAs in a robot design. This research aims to address these challenges by proposing a design framework for SMA-actuated smart structures in robotic applications. Drawing inspiration from nature, the initial step in this framework involves conceptualizing a multifunctional grasper. This grasper utilizes SMA springs actuated by electric current, enabling various movements such as crawling, grasping, and folding. Analytical modeling is employed to determine the necessary characteristics of the SMA springs for one segment of the grasper. A multi-body modeling approach is utilized for more comprehensive understanding of the robot performance. This approach verifies the results of the analytical modeling and allows for performance optimization. Grasper’s dynamics is enhanced by fine-tuning actuation input signals, resulting in a more precise, sustainable, and energy-efficient grasper that is capable of traveling 400% longer distance than the initial concept design. The conducted experiments confirm that the proposed design framework for mechanically intelligent grasper has the potential to streamline the SMA-actuated structure design process by reducing development time, minimizing the trial-and-error iterations, and yielding cost savings in both development and prototyping phases.

The design freedom of the additive manufacturing (AM) process has created new avenues for compliant mechanisms to have more complex geometries, functionality, and mechanical behavior than conventional manufacturing methods offer. However, the challenge in the assumption of 'free complexity' in AM is the trial-and-error often involved in creating a design that behaves as intended. To address this problem, a synthesis method incorporating nonlinear-elastic materials and large deformations as geometric nonlinearity is proposed, using an assembly of building blocks to construct a compliant mechanism. Designs generated by the model illustrate the optimization of the building block selection, size, shape, and topology to achieve different deflected states. The combination of the superelastic behavior of shape memory alloys such as Nitinol, and the exploration of different building block geometries, has been shown to enhance the flexibility of the optimized mechanism to reach such target shapes.