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Rod-based Fabrication of Customizable Soft Robotic Pneumatic Gripper Devices for Delicate Tissue Manipulation
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Pellet Printing for Soft Robotic Devices.

Yijia Wu1, Ju-Hung Chen1, Ariana Olivares1

  • 1Department of Mechanical Engineering, Tufts University, Medford, USA.

Advanced Science (Weinheim, Baden-Wurttemberg, Germany)
|March 23, 2026
PubMed
Summary
This summary is machine-generated.

Fused Granulate Fabrication (FGF) enables scalable, high-throughput 3D printing of soft robotic devices using thermoplastic pellets. This method provides access to diverse materials and produces durable, airtight pneumatic structures cost-effectively.

Keywords:
3D printingadditive manufacturingfused granulate fabricationsoft robotsthermoplastic elastomers

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Area of Science:

  • Robotics
  • Materials Science
  • Additive Manufacturing

Background:

  • Traditional soft robotic device fabrication methods (manual, additive manufacturing) face limitations in material choice and post-processing.
  • Existing techniques struggle with scalability and material versatility for complex soft structures.

Purpose of the Study:

  • To demonstrate Fused Granulate Fabrication (FGF) as a scalable and versatile method for rapid prototyping of soft robotic devices.
  • To overcome challenges in printing airtight pneumatic soft structures using FGF.
  • To establish material selection guidelines for FGF based on rheological properties and performance.

Main Methods:

  • Utilized a screw-based extruder for Fused Granulate Fabrication (FGF) of thermoplastic pellets.
  • Implemented hardware optimization and a material-centered printing strategy to address extrusion inconsistencies and stringing.
  • Conducted extrusion and oozing tests to develop material-specific performance profiles linked to rheological descriptors.

Main Results:

  • Achieved reliable 3D printing of airtight pneumatic soft structures at high volumetric flow rates (up to 5 mm³/s).
  • Demonstrated FGF's capability to process a wide range of materials, including soft elastomers (Shore 6A).
  • Fabricated pneumatic actuators showed durability exceeding 100,000 bending cycles, with mechanical performance comparable to silicone elastomers.

Conclusions:

  • FGF offers a cost-effective, scalable, and versatile alternative for digital fabrication of large-scale, airtight soft robotic devices.
  • The developed material-specific guidelines facilitate material selection for optimized FGF printing.
  • FGF enables the use of commercially available thermoplastic pellets, expanding material accessibility for soft robotics.