A Worm-like Crawling Soft Robot with Pneumatic Actuators Based on Selective Laser Sintering of TPU Powder

Soft robotics is one of the most popular areas in the field of robotics due to advancements in bionic technology, novel materials, and additive manufacturing. Existing soft crawling robots with specific structures have a single locomotion mode and cannot complete turning. Moreover, some silicone-based robots lack stiffness, leading to unstable movements especially when climbing walls, and have limited environmental adaptability. Therefore, in this study, a novel crawling soft robot with a multi-movement mode and high environmental adaptability is proposed. As the main structure of the robot, pneumatic single-channeled and double-channeled actuators are designed, inspired by the worm’s somite expansion and contraction. Model-based methods are employed to evaluate and analyze the characteristics of the actuators. By the application of selective laser sintering technology and thermoplastic polyurethane (TPU) material, the fabricated actuators with an auxetic cavity structure are able to maintain a certain stiffness. Via the coordination between the actuators and the suckers, two locomotion modes—straight-line and turning—are realized. In the testing, the speed of straight-line crawling was 7.15 mm/s, and the single maximum turning angle was 28.8 degrees. The testing verified that the robot could realize crawling on flat ground, slopes, and smooth vertical walls with a certain stability and equipment-carrying capacity. This research could lay the foundation for subsequent applications, including large tank interior inspections, civil aviation fuselage and wing inspections, and wall-cleaning in high-rise buildings.