This paper explores the deflection and buckling of fixed-guided beams used in compliant mechanisms. The paper’s main contributions include the addition of an axial deflection model to existing beam bending models, the exploration of the deflection domain of a fixed-guided beam, and the demonstration that nonlinear finite element models typically incorrectly predict a beam’s buckling mode unless unrealistic constraints are placed on the beam. It uses an analytical model for predicting the reaction forces, moments, and buckling modes of a fixed-guided beam undergoing large deflections. The model for the bending behavior of the beam is found using elliptic integrals. A model for the axial deflection of the buckling beam is also developed. These two models are combined to predict the performance of a beam undergoing large deflections including higher order buckling modes. The force versus displacement predictions of the model are compared to the experimental force versus deflection data of a bistable mechanism and a thermomechanical in-plane microactuator (TIM). The combined models show good agreement with the force versus deflection data for each device.

Tristable mechanisms, or devices with three distinct stable equilibrium positions, have promise for future applications, but the complexities of the tristable behavior have made it difficult to identify configurations that can achieve tristable behavior while meeting practical stress and fabrication constraints. This paper describes a new tristable configuration that employs orthogonally oriented compliant mechanisms that result in tristable mechanics that are readily visualized. The functional principles are described and design models are derived. Feasibility is conclusively demonstrated by the successful operation of four embodiments covering a range of size regimes, materials, and fabrication processes. Tested devices include an in-plane tristable macroscale mechanism, a tristable lamina emergent mechanism, a tristable micromechanism made using a carbon nanotube-based fabrication process, and a polycrystalline silicon micromechanism.

This paper presents the development of an origami-inspired support system (the OriGuide) that enables the insertion of flexible instruments using medical robots. Varying parameters of a triangulated cylindrical origami pattern were combined to create an effective highly compressible anti-buckling system that maintains a constant inner diameter for supporting an instrument and a constant outer diameter throughout actuation. The proposed origami pattern is composed of two repeated patterns: a bistable pattern to create support points to mitigate flexible shaft buckling and a monostable pattern to enable axial extension and compression of the support system. The origami-based portion of the device is combined with two rigid mounts for interfacing with the medical robot. The origami-based portion of the device is fabricated from a single sheet of polyethylene terephthalate. The length, outer diameter, and inner diameter that emerge from the fold pattern can be customized to accommodate various robot designs and flexible instrument geometries without increasing the part count. The support system also adds protection to the instrument from external contamination.

We present a new technique for fabricating compliant mechanisms from stamped metal sheets. The concept works by providing thinned segments to allow rotation of flexural beams 90 deg about their long axis, effectively providing a flexure as wide as the sheet’s thickness. The method is demonstrated with the design and fabrication of a metal bistable mechanism for use as a threshold accelerometer. A new model based on elliptic integral solutions is presented for bistable mechanisms incorporating long, thin flexures. The resulting metal bistable mechanisms are tested for acceleration threshold sensing using a drop test and a vibration test. The mechanisms demonstrate very little variation due to stress relaxation or temperature effects. The force-displacement behavior of a mechanism is also measured. The mechanisms’ switching force is less than the designed value because of out-of-plane motion and dynamic effects.

This paper presents a biological microelectromechanical system for injecting foreign particles into thousands of cells simultaneously. The system inserts an array of microneedles into a monolayer of cells, and the foreign particles enter the cells by diffusion. The needle array is fabricated using a series of deep reactive ion etches and produces about 4 million needles that average 1 μm in diameter and 8 μm in length with 10 μm spacing. The insertion of the needles is controlled through a compliant suspension. The compliant suspension was designed to provide for needle motion into the cells while restraining rotations or transverse motions that could result in tearing of the cell membranes. Testing was performed using propidium iodide, a membrane impermeable dye, injected into HeLa cells. Average cell survivability was found to be 97.7%, and up to 97.9% of the surviving cells received the propidium iodide.