Cable-driven continuum robots offer high flexibility and lightweight design, making them well-suited for tasks in constrained and unstructured environments. However, prolonged use can induce mechanical fatigue from plastic deformation and material degradation, compromising performance and risking structural failure. In the state of the art, fatigue estimation of continuum robots remains underexplored, limiting long-term operation. To address this, we propose a fatigue-aware continuum robot with three key innovations: (1) a Hybrid Hinge-Beam structure where TwistBeam and BendBeam decouple torsion and bending: passive revolute joints in the BendBeam mitigate stress concentration, while TwistBeam's limited torsional deformation reduces BendBeam stress magnitude, enhancing durability; (2) a Passive Stopper that safely constrains motion via mechanical constraints and employs motor torque sensing to detect corresponding limit torque, ensuring safety and enabling data collection; and (3) a real-time fatigue-awareness method that estimates stiffness from motor torque at the limit pose, enabling online fatigue estimation without additional sensors. Experiments show that the proposed design reduces fatigue accumulation by about 49% compared with a conventional design, while passive mechanical limiting combined with motor-side sensing allows accurate estimation of structural fatigue and damage. These results confirm the effectiveness of the proposed architecture for safe and reliable long-term operation.

Residual stresses, which remain within a component after processing, can deteriorate performance. Accurately determining their full-field distributions is essential for optimizing the structural integrity and longevity. However, the experimental effort required for full-field characterization is impractical. Given these challenges, this work proposes a machine learning (ML) based Residual Stress Generator (RSG) to infer full-field stresses from limited measurements. An extensive dataset was initially constructed by performing numerous process simulations with a diverse parameter set. A ML model based on U-Net architecture was then trained to learn the underlying structure through systematic hyperparameter tuning. Then, the model's ability to generate simulated stresses was evaluated, and it was ultimately tested on actual characterization data to validate its effectiveness. The model's prediction of simulated stresses shows that it achieved excellent predictive accuracy and exhibited a significant degree of generalization, indicating that it successfully learnt the latent structure of residual stress distribution. The RSG's performance in predicting experimentally characterized data highlights the feasibility of the proposed approach in providing a comprehensive understanding of residual stress distributions from limited measurements, thereby significantly reducing experimental efforts.

In contrast to the assumptions of most existing Electromigration (EM) analysis tools, the evolution of EM-induced stress is inherently non-deterministic, influenced by factors such as input current fluctuations and manufacturing non-idealities. Traditional approaches for estimating stress variations typically involve computationally expensive and inefficient Monte Carlo simulations with industrial solvers, which quantify variations using mean and variance metrics. In this work, we introduce a novel machine learning-based framework, termed BPINNEM- Post, for efficient stochastic analysis of EM-induced postvoiding aging processes. This new approach integrates closedform analytical solutions with a Bayesian Physics-Informed Neural Network (BPINN) framework to accelerate the analysis for the first time. The closed-form solutions enforce physical laws at the individual wire segment level, while the BPINN ensures that physics constraints at inter-segment junctions are satisfied and stochastic behaviors are accurately modeled. By reducing the number of variables in the loss functions through the use of analytical solutions, our method significantly improves training efficiency without accuracy loss and naturally incorporates variational effects. Additionally, the analytical solutions effectively address the challenge of incorporating initial stress distributions in interconnect structures during post-void stress calculations. Numerical results demonstrate that BPINN-EM-Post achieves over 240x speedup compared to Monte Carlo simulations using the FEM-based COMSOL solver and more than 65x speedup compared to Monte Carlo simulations using the FDM-based EMSpice method.

Grasping is fundamental to robotic manipulation, and recent advances in large-scale grasping datasets have provided essential training data and evaluation benchmarks, accelerating the development of learning-based methods for robust object grasping. However, most existing datasets exclude deformable bodies due to the lack of scalable, robust simulation pipelines, limiting the development of generalizable models for compliant grippers and soft manipulands. To address these challenges, we present GRIP, a General Robotic Incremental Potential contact simulation dataset for universal grasping. GRIP leverages an optimized Incremental Potential Contact (IPC)-based simulator for multi-environment data generation, achieving up to 48x speedup while ensuring efficient, intersection- and inversion-free simulations for compliant grippers and deformable objects. Our fully automated pipeline generates and evaluates diverse grasp interactions across 1,200 objects and 100,000 grasp poses, incorporating both soft and rigid grippers. The GRIP dataset enables applications such as neural grasp generation and stress field prediction.

This paper investigates the influence of the internal geometrical structure of soft pneu-nets on the dynamic response and hysteresis of the actuators. The research findings indicate that by strategically manipulating the stress distribution within soft robots, it is possible to enhance the dynamic response while reducing hysteresis. The study utilizes the Finite Element Method (FEM) and includes experimental validation through markerless motion tracking of the soft robot. In particular, the study examines actuator bending angles up to 500% strain while achieving 95% accuracy in predicting the bending angle. The results demonstrate that the particular design with the minimum air chamber width in the center significantly improves both high- and low-frequency hysteresis behavior by 21.5% while also enhancing dynamic response by 60% to 112% across various frequencies and peak-to-peak pressures. Consequently, the paper evaluates the effectiveness of "mechanically programming" stress distribution and distributed energy storage within soft robots to maximize their dynamic performance, offering direct benefits for control.

Soft biological tissues often have complex mechanical properties due to variation in structural components. In this paper, we develop a novel UNet-based neural network model for inversion in elasticity (El-UNet) to infer the spatial distributions of mechanical parameters from strain maps as input images, normal stress boundary conditions, and domain physics information. We show superior performance, both in terms of accuracy and computational cost, by El-UNet compared to fully-connected physics-informed neural networks in estimating unknown parameters and stress distributions for isotropic linear elasticity. We characterize different variations of El-UNet and propose a self-adaptive spatial loss weighting approach. To validate our inversion models, we performed various finite-element simulations of isotropic domains with heterogenous distributions of material parameters to generate synthetic data. El-UNet is faster and more accurate than the fully-connected physics-informed implementation in resolving the distribution of unknown fields. Among the tested models, the self-adaptive spatially weighted models had the most accurate reconstructions in equal computation times. The learned spatial weighting distribution visibly corresponded to regions that the unweighted models were resolving inaccurately. Our work demonstrates a computationally efficient inversion algorithm for elasticity imaging using convolutional neural networks and presents a potential fast framework for three-dimensional inverse elasticity problems that have proven unachievable through previously proposed methods.

Additive manufacturing has been recognized as an industrial technological revolution for manufacturing, which allows fabrication of materials with complex three-dimensional (3D) structures directly from computer-aided design models. The mechanical properties of interpenetrating phase composites (IPCs), especially response to dynamic loading, highly depend on their 3D structures. In general, for each specified structural design, it could take hours or days to perform either finite element analysis (FEA) or experiments to test the mechanical response of IPCs to a given dynamic load. To accelerate the physics-based prediction of mechanical properties of IPCs for various structural designs, we employ a deep neural operator (DNO) to learn the transient response of IPCs under dynamic loading as surrogate of physics-based FEA models. We consider a 3D IPC beam formed by two metals with a ratio of Young's modulus of 2.7, wherein random blocks of constituent materials are used to demonstrate the generality and robustness of the DNO model. To obtain FEA results of IPC properties, 5,000 random time-dependent strain loads generated by a Gaussian process kennel are applied to the 3D IPC beam, and the reaction forces and stress fields inside the IPC beam under various loading are collected. Subsequently, the DNO model is trained using an incremental learning method with sequence-to-sequence training implemented in JAX, leading to a 100X speedup compared to widely used vanilla deep operator network models. After an offline training, the DNO model can act as surrogate of physics-based FEA to predict the transient mechanical response in terms of reaction force and stress distribution of the IPCs to various strain loads in one second at an accuracy of 98%. Also, the learned operator is able to provide extended prediction of the IPC beam subject to longer random strain loads at a reasonably well accuracy.

For ensuring vehicle safety, the impact performance of wheels during wheel development must be ensured through a wheel impact test. However, manufacturing and testing a real wheel requires a significant time and money because developing an optimal wheel design requires numerous iterative processes to modify the wheel design and verify the safety performance. Accordingly, wheel impact tests have been replaced by computer simulations such as finite element analysis (FEA); however, it still incurs high computational costs for modeling and analysis, and requires FEA experts. In this study, we present an aluminum road wheel impact performance prediction model based on deep learning that replaces computationally expensive and time-consuming 3D FEA. For this purpose, 2D disk-view wheel image data, 3D wheel voxel data, and barrier mass values used for the wheel impact test were utilized as the inputs to predict the magnitude of the maximum von Mises stress, corresponding location, and the stress distribution of the 2D disk-view. The input data were first compressed into a latent space with a 3D convolutional variational autoencoder (cVAE) and 2D convolutional autoencoder (cAE). Subsequently, the fully connected layers were used to predict the impact performance, and a decoder was used to predict the stress distribution heatmap of the 2D disk-view. The proposed model can replace the impact test in the early wheel-development stage by predicting the impact performance in real-time and can be used without domain knowledge. The time required for the wheel development process can be reduced by using this mechanism.

Numerical analysis methods, such as Finite Element Analysis (FEA), are typically used to conduct stress analysis of various structures and systems for which it is impractical or hard to determine an analytical solution. Researchers commonly use FEA methods to evaluate the design, safety and maintenance of different structures in various fields, including aerospace, automotive, architecture and civil structural systems. The current workflow for FEA applications includes: (i) modeling the geometry and its components, (ii) specifying material properties, boundary conditions, meshing, and loading, (iii) dynamic analysis, which may be time-consuming based on the complexity of the model. The time requirement constraint and the complexity of the current FEA workflow make it impractical for real-time or near real-time applications, such as in the aftermath of a disaster or during extreme disruptive events that require immediate corrections to avoid catastrophic failures. Based on the steps of FEA described above, performing a complete stress analysis with conventional FEA has a high computational cost.

Structural failures are often caused by catastrophic events such as earthquakes and winds. As a result, it is crucial to predict dynamic stress distributions during highly disruptive events in real time. Currently available high-fidelity methods, such as Finite Element Models (FEMs), suffer from their inherent high complexity. Therefore, to reduce computational cost while maintaining accuracy, a Physics Informed Neural Network (PINN), PINN-Stress model, is proposed to predict the entire sequence of stress distribution based on Finite Element simulations using a partial differential equation (PDE) solver. Using automatic differentiation, we embed a PDE into a deep neural network's loss function to incorporate information from measurements and PDEs. The PINN-Stress model can predict the sequence of stress distribution in almost real-time and can generalize better than the model without PINN.