Engineers at the University of Oxford have developed a remarkably simple and inexpensive way to build soft robots.
Using common laboratory tools and low-cost materials, the new method allows researchers to create soft robotic components in less than 10 minutes for under 10 cents each.
The research, published in the journal Advanced Science, could make soft robotics more accessible to scientists, students, and start-up companies by dramatically lowering the cost and complexity of manufacturing.
Soft robots are different from traditional rigid machines.
Instead of metal joints and motors, they are made from flexible materials that can bend, stretch, and deform.
Because of this flexibility, soft robots are especially useful for tasks that require gentle or adaptable movements. Scientists are exploring their use in areas such as delicate object handling, wearable devices, medical tools, and even search-and-rescue operations.
Despite their potential, building soft robots has often required specialized equipment and complex processes.
Traditional manufacturing methods may involve silicone molds, advanced 3D printers, or layered textile materials. These techniques can be expensive and time-consuming, limiting how quickly researchers can experiment with new designs.
The Oxford team set out to create a faster and cheaper alternative. Their approach uses everyday thermoplastic vacuum-sealable pouches, similar to those commonly used for food storage.
By combining these plastic pouches with a vacuum sealing machine and a laser cutter, the researchers developed a simple way to create flexible robotic actuators.
Actuators are the parts of a robot responsible for movement. In soft robots, these components often inflate or bend to produce motion.
In the new technique, air is first removed from the plastic pouch using a standard vacuum sealing machine. Then a laser cutter precisely seals and cuts the material into the desired shape. This single step both forms the actuator and seals the edges, creating inflatable structures that move when filled with air.
Once pressurized, the actuators bend in predictable ways. By carefully designing the shape of the cuts, the researchers can control how the actuator moves. This allows engineers to “program” different motions directly into the material.
Using the method, the team created several working soft robots. These included a robotic gripper capable of lifting objects weighing 25 times more than the robot itself. They also built lightweight crawling and swimming robots, demonstrating the technique’s versatility.
To test the durability of the devices, the researchers repeatedly inflated and deflated the actuators. The structures survived up to 100,000 cycles while still producing strong forces at relatively low air pressure.
The team also developed a computer-based design system that helps engineers plan how the actuators will bend. By adjusting geometric patterns, designers can produce shapes such as spirals or even letters.
Interestingly, the method also opens opportunities beyond research labs. The team created inflatable animal shapes, including turtles and cranes, to demonstrate how the technique could be used in creative and educational settings. These simple and visually engaging designs could help attract students to robotics and engineering.
Looking ahead, the researchers plan to explore additional plastic materials and investigate ways to produce more complex motions, such as twisting or multi-directional bending.
By making soft robots faster and cheaper to build, the new technique could speed up innovation in robotics and help bring flexible robotic technologies into many new fields.
