The minimum number of bodies required to form a closed kinematic chain capable of motion is four. A planar fourbar mechanism has one degree of freedom (DOF), whereas in three-dimensional space, it becomes over-constrained, reducing its DOF to negative two. While the kinematic ide
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The minimum number of bodies required to form a closed kinematic chain capable of motion is four. A planar fourbar mechanism has one degree of freedom (DOF), whereas in three-dimensional space, it becomes over-constrained, reducing its DOF to negative two. While the kinematic idealization remains unaffected, its physical realization introduces conflicting constraints. This study deliberately incorporates misaligned overconstraints in four-bar mechanisms to achieve tailorable load displacement characteristics by utilizing a compliant coupler link. Such tunable characteristics could potentially eliminate the need for traditional springs and dampers in mechanical systems. A positioning strategy for misaligned over-constraints is developed. An Euler-Bernoulli beam model with superposition is employed to analyze how misalignments influence the loaddisplacement response. Additionally, a numerical model using Simscape Multibody is implemented to verify the analytical results. To further validate the findings, a modular physical prototype is constructed and tested to compare real-world behavior with computational models. The numerical simulations effectively capture the response of the four-bar mechanism, considering elastic deformations in the compliant coupler link. The results from all models exhibit strong agreement. Parameter relaxation is introduced to account for manufacturing tolerances and geometric imperfections. Furthermore, a parametric study is conducted to examine the influence of individual design parameters on the load-displacement characteristics. To facilitate design exploration, a graphical user interface (GUI) is developed, enabling users to tailor four-bar mechanisms based on specific load-displacement requirements. Two distinctive behaviors are presented: extended regions of nearly constant torque and sinusoidal load-displacement characteristics, both of which have potential applications in precision engineering and motion control.