Proper positioning of Microelectromechanical Systems (MEMS) components influences the functionality of the device, especially in devices where the motion is in the range of hundreds of micrometers. There are two main obstacles to positioning: off-axis displacement, and position determination. This work studies four large-displacement devices, their axial and transverse stiffness, and piezoresistive response. Methods for improving the device characteristics are described. The folded-beam suspension, small X-Bob, large X-Bob and double X-Bob were characterized using non-dimensional metrics that measure the displacement with regard to the size of the device, and transverse stiffness with regard to axial stiffness. The stiffness in each direction was determined using microprobes to induce displacement, and microfabricated force gauges to determine the applied force. The large X-Bob was optimized, increasing the transverse stiffness metric by 67%. Four-point resistance testing and microprobes were used to determine the piezoresistive response of the devices. The piezoresistive response of the X-Bob was maximized using an optimization routine. The resulting piezoresistive response was over seven times larger than that of the initial design. Piezoresistive encoders for ratcheting actuation of large-displacement MEMS are introduced. Four encoders were studied and were found to provide information on the performance of the ratcheting actuation system at frequencies up to 920 Hz. The PMT encoder produced unique signals corresponding to distinct ideal and non-ideal operation of the ratchet wheel actuation system. Encoders may be useful for future applications which require position determination.

This thesis introduces new revolute and torsional lamina emergent mechanism (LEM) flexure designs that are suited for use in metals. Previous LEM flexures have been designed for use in highly elastic materials, such as polymers. In extending LEM flexure designs to metals, a LEM flexure design criteria is also introduced. The LEM flexure criteria is based on relative performance between the LEM flexure and a performance datum which the LEM flexure must improve upon. This performance datum, or benchmark, is a section of lamina that is of the same overall length, width, and thickness as the LEM flexure. An analysis of the revolute and torsional metal LEM flexures, based on the LEM flexure criteria, is performed and both are found to successfully meet the criteria. A brief comparative performance study is also carried out between a basic crank-slider mechanism to which the revolute and torsional metal LEM flexures have and have not been applied. The revolute and torsional metal LEM flexures are found to improve the crank-slider performance.

Limited resources are currently available to assist engineers in implementing compliant members into mechanical designs. As a result, engineers often have little to no direction incorporating compliant mechanisms. This thesis develops a conceptual design framework and process that utilizes a proposed classification scheme and a library of mechanisms to help engineers incorporate compliant mechanisms into their applications. As the knowledge related to the synthesis and analysis of compliant mechanisms continues to grow and mature, and through the classification scheme established in this thesis, compliant mechanisms may become more extensively used in commercial mechanical designs. This thesis also demonstrates a design approach engineers can use to convert an existing rigid-body mechanism into a compliant mechanism by using the established classification scheme and a library of compliant mechanisms. This approach proposes two possible techniques that use rigid-body replacement synthesis in conjunction with a compliant mechanism classification scheme. One technique replaces rigid-body elements with a respective compliant element. The other technique replaces a complex rigid-body mechanism by decomposing the mechanism into simpler functions and then replacing a respective rigid-body mechanism with a compliant mechanism that has a similar functionality. These techniques are then demonstrated by developing and designing a competitive and feasible compliant road bicycle brake system.

Haptic interfaces are robotic force-feedback devices that give the user a sense of touch as they interact with virtual or remote environments. These interfaces act as input devices, mapping the 3-dimensional (3D) motions of the user's hand into 3D motions in a slave system or simulated virtual world. A major challenge in haptic interfaces is ensuring that the user's experience is a realistic depiction of the simulated environment. This requires the interface's design to be such that it does not hinder the user's ability to feel the forces present in the environment. This "transparency" is achieved by minimizing the device's physical properties (e.g., weight, inertia, friction). The primary objective of the work is to utilize compliant mechanisms as a means to improve transparency of a haptic interface. This thesis presents work toward the design of a fully compliant mechanism that can be utilized in haptic interfaces as a means to reduce parasitic forces. The approach taken in this work is to design a series of mechanisms that when combined act as a statically balanced compliant joint (SBCJ). Simulated and experimental results show that the methods presented here result in a joint that displays a significant decrease in return-to-home behavior typically observed in compliant mechanisms. This reduction in the torque needed to displace the joint and the absence of friction suggest that the joint design is conducive to the methods previously proposed for increasing transparency in haptic interfaces.

The purpose of this research is to investigate the use of compliant mechanisms in space applications and design, analyze, and test a compliant space mechanism. Current space mechanisms are already highly refined and it is unclear if significant improvements in performance can be made by continuing to refine current designs. Compliant mechanisms offer a promising opportunity to change the fundamental approach to achieving controlled motion in space systems and have potential for dramatic increases in mechanism performance given the constraints of the space environment. A compliant deployment hinge was selected for development after industry input was gathered. Concepts for large-displacement compliant hinges are investigated. A design process was developed that links the performance requirements of deployment to the design parameters of a deployment hinge. A large-displacement monolithic compliant rotational hinge, the Flex-16, is designed, analyzed, and tested. It was developed for possible application as a spacecraft deployment hinge and designs were developed using three different materials (polypropylene, titanium, and carbon nanotubes) and manufacturing processes (CNC milling, electron beam manufacturing metal rapid prototyping, and a carbon nanotube framework) on two size scales (macro and micro). A parametric finite element model allowed for prediction of prototype behavior before fabrication. The Flex-16 hinge is capable of 90 degrees of deflection without failure or contact and can be designed to meet industry requirements for space.

Robotics and space applications represent areas where compliant mechanisms can continue to make a significant impact by reducing costs and weight while improving performance. Because of the nature of these applications, a common need is for bearing replacement mechanisms, or mechanisms that perform the function of a bearing without the complexity and failure modes associated with bearings. Static balancing is a design strategy that attempts to reduce the actuation effort of a mechanism, and has been applied to compliant mechanisms in some applications. Monolithic construction, especially by means of 3D printing technology, is a strategy whereby the mechanism links and joints are built as a single "chunk" of material. This eliminates assembly and failure modes associated with wear and friction in traditional joints. In this work we examine these design strategies in the context of robotics and space applications. Matlab and Ansys batch files can be found in Appendix A. A fully compliant zero-torque, statically balanced mechanism is described that can undergo greater than 100 of motion. Because compliant mechanisms achieve their motion from the deflection of their constituent members, there is some strain energy associated with actuated positions. By introducing an appropriate pre-load, strain energy can be held constant. This can reduce or nearly eliminate the input force required from the actuating device. This paper describes the statically balanced rotary joint concept, and demonstrates its optimization, testing, and implementation for a haptic pantograph mechanism. The statically balanced properties of the constituent joints result in a mechanism with two balanced degrees of freedom. Matlab and Ansys batch files can be found in Appendix B. The conception, modeling, and development of a fully compliant two-degree-of-freedom pointing mechanism for application in spacecraft thruster, antenna, or solar array systems is described. The design objectives and the advantages of a compliant solution are briefly discussed. A single design concept is selected for final development from a field of generated concepts. Analytical and numerical models are accompanied by prototype testing and measurements in several iterations. A final design is described in detail, a fully compliant prototype is fabricated in titanium, and its performance is measured.

Origami can be a powerful source of design inspiration in the creation of reconfigurable systems with unparalleled performance. This thesis provides fundamental tools for designers to employ as origami-based designs are pursued in their respective fields of expertise. The first chapter introduces origami and makes connections between origami and engineering design through a survey of engineered applications and characterizing the relationship between origami and compliant mechanisms. The second chapter evaluates the creasing of non-paper sheet materials, such as plastics and metals, to facilitate origami-based compliant mechanism design. Although it is anticipated that most origami-based design will result from surrogate folds (indirect methods of replacing the crease), it is valuable to provide information that may help in more direct approaches for origami-based design in materials other than paper. Planar sheets of homogeneous material are considered as they maintain the principles fundamental to origami (flat initial state, low cost, readily available). The reduced stiffness along the axis of the crease is an enabling characteristic of origami. Hence a metric based on the deformation of the crease compared to the deformation of the panels enables engineering materials to be evaluated based on their ability to achieve the "hinge-like" behavior observed in folded paper. Advantages of both high and low values of this metric are given. Testing results (hinge indexes, residual angles, localized hinge behavior and cyclic creasing to failure) are presented for various metals and polymers. This methodology and subsequent findings are provided to enable origami-based design of compliant mechanisms. The third chapter proposes a basic terminology for origami-based design and presents areas of considerations for cases where the final engineering design is directly related to a crease pattern. This framework for navigating from paper art to engineered products begins once the crease pattern has been selected for a given application. The four areas of consideration are discussed: 1) rigid foldability 2) crease characterization 3) material properties and dimensions and 4) manufacturing. Two examples are concurrently presented to illustrate these considerations: a backpack shell and a shroud for an adjustable C-Arm x-ray device used in hospitals. The final chapter provides concluding remarks on origami-based design.

Origami-inspired design is an emerging field capable of producing compact and efficient designs. The object of a surrogate fold is to provide a fold-like motion in a non-paper material without undergoing yielding. Compliant mechanisms provide a means to achieve these objectives as large deflections are achieved. The purpose of this thesis is to present a summary of existing compliant joints suitable for use as surrogate folds. In doing so, motions are characterized which no existing compliant joint provides. A series of compliant joints is proposed which provides many of these motions. The possibility of patterning compliant joints to form an array is discussed. Arrays capable of producing interesting motions are noted.

This thesis addresses a number of challenges designers face when designing deployable origami-based arrays, specifically joint selection, design, and placement within an array. In deployable systems, the selection and arrangement of joint types is key to how the system functions. The kinematics and performance of an array is directly affected by joint performance. This work develops joint metrics which are then used to compare joint performances, constructing a tool designers can use when selecting joints for an origami array. While often a single type of joint is used throughout an array, this work shows how using multiple types of joints within the same array can offer benefits for motion deployment, and array stiffening. Origami arrays are often used for their unique solutions for stowing and deploying large planar shapes. Folds, enabled through joints, within these patterns allow the arrays to fold compactly. However, it can be difficult to fully deploy arrays, particularly array designs with a high number of joints. In addition, it is a challenge to stabilize a fully deployed array from undesired re-folding. This work introduces a strain-energy storing joint that is used to deploy and stiffen foldable origami arrays, the Lenticular Lock (LentLock). Geometry of the LentLock is introduced and the deploying and stiffening performance of the joint is shown. Folds within an origami array create the constraints that link motion between panels, and can be used to create kinematic benefits, such as creating mechanisms with a single degree-of-freedom. While many fold-constraints are required to define motion, this work shows that origami-based system contain many redundant constraints. The removal of redundant joints does not affect the motion of the array nor the observed mobility, but may decrease the likelihood of binding, simplify the overall system and decrease actuation force. This work introduces a visual and iterative approach designers can use to identify redundant constraints in origami patterns, and techniques that can be used to remove the identified redundant constraints. The presented techniques are demonstrated by removing redundant constraints from prototyped origami mechanisms. As a result of this work, designers will be better able to approach and design deployable origami-based mechanisms.

Robotic surgery procedures may include long, thin flexible instruments that are inserted by the robot into the patient. As the robot inserts these devices, due to their geometry, they are prone to buckling failure. To mitigate buckling failure, a support system is needed on the robot. This system supports the device but also adapts to the varying ex vivo length of the device as it is inserted. This work presents four collapsible support systems designed to mitigate buckling failure of long, thin instruments while accounting for changing length. The Ori-Guide is an origami-inspired system that has enabled a part reduction from traditional rigid systems with over 70 parts to 3 parts. This system was enabled through the development of a novel origami pattern that integrates both actuation and support into the same pattern. This system was made from PET and performed as well as a rigid system. The PET used in the Ori-Guide was thermo-processed to hold a folded shape. The heat treatment put the Ori-Guide into tension and enabled a stiffer support system. Work was done to investigate the effect of thermo-processing on PET films used in origami-inspired engineering applications. It was discovered that there is a strong correlation between crystallization and the stiffness of a crease in the polymer film. The Zipper-Tube Reinforcement (ZTR) was developed to provide constant support along the entire length of the device, something that no other support device provides. This enables higher loads on the device and thinner and more flexible devices. It was developed as a tube that envelopes the device and zips to provide a tube to support the device then unzips to lay flat rolled about a mandrel for storage. The Wires in Tension concept was developed by focusing on adding tension to the support system. It provided support to the device but required high levels of force on the robot arm so the Orthogonal Beams was developed. The Orthogonal Beams employs geometry as the primary support rather than tension and therefore could provide higher support with less force on the robot. These systems all proved effective ways to support flexible devices. The concepts could also find application in other fields. The merits of each system are discussed in detail, including a discussion on other possible applications.