Concept for a 3D-printed soft rotary actuator driven by a shape-memory alloy

In line with the recent development of soft actuators involving shape-memory alloys (SMAs) embedded in compliant structures, this paper proposes a concept for a rotary actuator driven by a SMA wire placed inside a 3D-printed helical structure. The concept consists of using the one-way memory effect of the SMA (activated by Joule heating) to create the rotation of a material point of the structure, while the inverse rotation is obtained during the return to ambient temperature thanks to the structure's elasticity. The study was performed in three steps. First, a prototype was designed from a chain of design rules, and tested to validate the feasibility of the concept. Thermal and geometrical measurements were performed using infrared and visible-range stereo cameras. A clockwise rotation (250°) followed by an anti-clockwise rotation (−200°) were obtained, enabling us to validate the concept despite the partial reversibility of the movement. Second, finite element simulations were performed to improve rotation reversibility. The high compliance of the mechanical system required a framework of large displacements for the calculations (in the strength of materials sense), due to the high structural flexibility. Finally, a second prototype was constructed and tested. Attention was paid to the rotation (fully reversible rotation of 150° reached) as well as to parasitic movements due to overall structural deformation. This study opens new prospects for the design and analysis of 3D-printed soft actuators activated by smart materials.