Printed helicoids with embedded air channels make sensorized segments for soft continuum robots

Abstract

Soft robots enable safe, adaptive interaction with complex environments but remain difficult to sense and control due to their highly deformable structures. Architected soft materials such as helicoid lattices offer tunable stiffness and strength but are challenging to instrument because of their sparse geometry. We introduce a fabrication method for embedding air channels into helicoid-based soft continuum robots. Multi-material segments fabricated via vision-controlled jetting in a single print interface with PCBs housing miniature pressure sensors and IMUs for distributed deformation sensing. We characterize the mechanical properties of four helicoid designs and validate the sensor response to fundamental deformation modes. To demonstrate the platform's scalability, we construct and mechanically evaluate a meter-scale, 14-DoF cable-driven soft arm capable of open-loop trajectory tracking and object grasping, with tactile-based stiffness detection demonstrated using the gripper sensors. This approach establishes a scalable fabrication strategy for sensorized architected materials in large-scale soft robotic systems.