Multilayer pouch robot devices and methods of manufacture

Abstract

Soft inflatable pouch robots with many independent degrees of freedom are created from multiple layers of thin thermoplastic films. The method uses inkjet-printed solvent ink or laser printer toner to pattern pouch layers, enabling the integration of pouch actuators, structures, channels, and pneumatic ports within one process. A fluid manifold allows addressable and controlled inflation of the inflatable features of the device. A 4-finger 8-independent-DoF pouch hand performing in-hand manipulation, and a 10-independent-DoF continuum manipulator performing planar pick-and-place illustrate the design functionalities.

Description

MULTILAYER POUCH ROBOT DEVICES AND METHODS OF MANUFACTURECROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to, and the benefit of, U.S. provisional patent application serial number 63 / 704,832 filed on October 8, 2024, incorporated herein by reference in its entirety.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not ApplicableNOTICE OF MATERIAL SUBJECT TO COPYRIGHT PROTECTION

[0003] A portion of the material in this patent document may be subject to copyright protection under the copyright laws of the United States and of other countries. The owner of the copyright rights has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the United States Patent and Trademark Office publicly available file or records but otherwise reserves all copyright rights whatsoever. The copyright owner does not hereby waive any of its rights to have this patent document maintained in secrecy, including without limitation its rights pursuant to 37 C. F. R. § 1 .14.BACKGROUND

[0004] 1. Technical Field

[0005] This technology pertains generally to thin film laminate devices and construction methods and more particularly to rapid, monolithic, and scalable method for fabricating multi-layer pouch robots with controllable inflatable members. Leveraging inkjet or toner printing for depositing a separating layer to prevent bonding, the methods can create inflatable structures of any planar geometry on multiple layers, with a minimum channel size of approximately 0.3 mm. The methods permit the fabrication of a wide range of soft miniatureBK-2024-162-2-PCT -1-actuated mechanisms, including devices such as highly articulated soft surgical robots which allow access for inspection, such as with a camera, or for a biopsy without hurting surrounding delicate tissue.

[0006] 2. Background

[0007] Traditional robot devices are built with rigid joints and links for high precision movements and force. Soft robots, on the other hand, are typically composed of both soft joints and links, enabling high degrees of freedom, compliance, and adaptability to unstructured environments.

[0008] Inflatables that are made with relatively inextensible thin films, or pouches, have gained significant interest in soft robot design because of their large expansion ratio, high speed, and tunable stiffness via inflation. Often made from sealed thermoplastic films, these pouches are initially flat and experience a large volume expansion upon inflation. They are easy to design, fabricate, and scale compared to other pneumatic elements such as the ones made from elastomers which typically require 3D molding and curing steps or 3D printing. In contrast, thermoplastic films are sealed via heat, and their planarity makes pouches well-suited for 2D fabrication methods. Pouches are often used as actuators in robots along with rigid elements as structure, creating hybrid rigid-soft robots.

[0009] Conventional soft pouch robots, or robots that use thin-film pouches for both actuation and structure, have a limited number of inputs and independent Degrees-of-Freedom (DoF), thus restricting their functionality. For example, 1 -input gripper with two coupled 1-DoF fingers and a 1 -input, eight coupled actuator DoF forward-swimming robot have been developed.

[0010] To increase complexity, individual pouch actuators are sometimes connected manually with adhesives and external pneumatic tubing to create robots with a higher number of independent DoFs. Without a process to automatically integrate mechanical and pneumatic connections, previous pouch robot designs have been difficult to scale in independent DoFs and sizes.

[0011] Current fabrication methods are a central limitation to creating integrated soft pouch robots with multiple independent DoFs. One class of fabrication methods uses a targeted heat source (e.g., hot air gun, laser,BK-2024-162-2-PCT -2-soldering iron, patterned metal stencils, or impulse sealer) to directly define the pouch geometry by welding its outline. Impulse sealers are widely used to create linear contracting pouch actuators and bending actuators. While easy to implement, it is difficult to control the heat source to only fuse specific layers in a multi-layer stack, limiting the capability of multiple layers to have independent designs.

[0012] Another class of methods places an additional layer in between adjoining film layers, which functions as either a bonding or blocking agent and is patterned according to pouch geometry, thereby creating unfused pouch regions when a uniform heat source (e.g., heat press, laminator) is applied. These methods have shorter per-layer processing times compared to sequential drawing methods and enable parallel fusing of multiple layers. However, the added bonding / blocking layer can introduce significant height differences per film layer, resulting in inconsistent bonding and all pouch layers need to have a similar design. In other known methods, the added film layers for masking / bonding are positioned manually, limiting feature resolution.

[0013] Overall, current fabrication methods have large minimum feature sizes and a limited capability for building multi-layer pouches. Multi-layer pouch integration is key for incorporating multiple control channels and independent DoFs without creating weak uninflated regions.

[0014] Accordingly, there is a need for improved fabrication methods to produce small-scale devices with multiple independent DoFs and reliable and predictable features.BRIEF SUMMARY

[0015] Inflatable pouches are attractive as actuators and structural links in soft robots due to their low deflated profile and high deformation ratios. Fabrication remains a key limitation to developing multi-DOF, Multi-Input Multi-Output (MIMO) pouch robots. Current methods of fabrication do not readily scale to less than 2 mm feature sizes, cannot incorporate multiple layers, or require all layers to have similar designs.

[0016] The present technology provides fabrication methods that can produceBK-2024-162-2-PCT -3-devices with multi-layer inflatable pouches of any planar geometry that are created using thermal fusing, with inter-layer connections and a minimum feature resolution of approximately 0.3 mm. The multi-layer fabrication process enables the integration of pouches for bending actuation and structure, pneumatic channels, and external port connections. This high level of integration enables the fabrication of pouch robots with many independent DoFs. The structural elements include inflatable pouches and patterned structures, making the entire robot collapsible and able to fit in small channels.

[0017] The fabrication methods are referred to as IMPRINT (Integrated Multilayer Pouch Robots with I Nkjet- patterned Thin-films), a rapid and monolithic method for fabricating multi-layer pouch robots that are illustrated in FIG. 1 , FIG. 2 and FIG. 3. The methods overcome the requirement of precision handling of separator films, or limited multilayer integration capability, with the use of a solvent-based ink or a laser-printed toner provides a release layer between two heat-fused plastic layers, creating channels and pouch actuators when pressurized. Using a commercial micro-piezo inkjet printer, small features (less than 0.3 mm) are patterned on plastic layers at a high speed while maintaining film planarity.

[0018] Alternatively, a commercial laser printer can apply patterns of toner on a transfer film to pattern small features on plastic layers. By heat pressing multiple inkjet-printed or toner-printed layers together, the method can create inflatable pouches of any planar geometry on multiple layers, with laser cut through holes for connection ports to a manifold.

[0019] For example, the methods permit the production of multilayer soft robot structures with two pouch actuator layers for bidirectional bending, and a third pouch layer to provide controllable rigidity to robot links. The manufacturing methods allow the creation of complicated structures with less than 1 mm feature size including a miniature four finger hand which can dexterously manipulate a cube, and a ten degree-of-freedom planar manipulator with a gripper which can maneuver around obstacles.

[0020] The entire pouch robot structure can have an un-inflated thickness of less than 300 pm, and is inherently soft, making pouch robots attractive forBK-2024-162-2-PCT -4-surgical applications. With this fabrication method, thin-film materials that are otherwise stationary are functionalized to be able to move and bend in multiple degrees of freedom, while its soft, air-filled pouches exert a limited amount of force on the environment. This allows the robot to be used in tight spaces with fragile tissues for surgical applications, for example.

[0021] One embodiment of the current invention provides a method to fabricate a wide range of soft miniature actuated mechanisms, including devices such as highly articulated soft surgical robots which allow access for inspection such as with a camera, or for a biopsy without hurting surrounding delicate tissue. The device materials can be chosen from biocompatible thermoplastics such as LDPE, HDPE, etc.

[0022] The IMPRINT fabrication process is demonstrated with base components for integrated robots including uni-directional and bi-directional bending actuators and structural links that are fabricated and characterized individually. One embodiment of the fabrication process incorporates: 1 ) variable-inflated single- and bi-directional bending joints, 2) constant-inflated structural links, 3) integrated air channels, and 4) connection ports to the manifold.

[0023] The IMPRINT fabrication methods are also demonstrated with: 1 ) a 4- finger, 13-input, 8-independent-DoF 38 mm-wide robot hand for dexterous manipulation; and 2) a 12-input, 10-independent-DoF, 42 mm-wide, 138 mm- long continuum manipulator for planar pick-and-place. These robots have completely soft actuator joints and structural links, sub-millimeter features, and are attached to rigid air supply manifolds at their base.

[0024] The term “layer of a material” is intended to have a broad definition that can include a single polymer film in some embodiments or can be a combination of more than one sublayer in other embodiments. For example, the layer of material can be two or more layers of polymer films in some embodiments or could include sublayers that are not polymers and / or not films, for example. The sublayers can be of the same materials or different materials in any combination. In some embodiments, the layer of material can include one or more sublayers that are not films, such as, but not limited to, one or more woven layer of material or rip-stop nylon layer, for example. TheBK-2024-162-2-PCT -5-one or more layers of polymer film can include materials such as LDPE, HDPE, IIHMW, PE, PP, PET, TPE, TPU, or any combination thereof.

[0025] In some embodiments the polymer film can also have a special coating such as an adhesive coating or metallized film coating. In some embodiments a shape-memory polymer film can be included. In some embodiments one or more layers of reinforcement film can be included, for example reinforced with cloth, fiber, cellulose, and / or polyimide (Kapton™). In some embodiments one or more layers of adhesive film can be included. For example, a thermal- activated adhesive and / or a pressure-sensitive adhesive. In some embodiments one or more layers of elastic films can be included such as, but not limited to, silicone rubber. In some embodiments one or more layers of partially conductive and / or variable conductive films can be included, such as various metal films.

[0026] The term “Ink” refers to a solvent-based ink that is used to print a mask. Solvent based inks provide good adhesion to LDPE, a small lateral resolution allowing smaller feature size than painting with a pen, and produces a thinner layer than paint, which allows multilayer integration. There are other classes of ink that could be substituted in place of solvent-based ink in the fabrication process, depending on the film material and processing temperatures. UV-curable inks, which cure instantly when exposed to UV light, can be used in place of solvent-based ink when fast drying of ink on film is needed, or for less environmental impacts. Water-based inks including latex, pigment-based, and dye-based inks have limited adhesion to non- porous surfaces (such as plastic films) but could be advantageous if the film layers are porous, or if low levels of volatile organic compounds (VOCs) are required.

[0027] The term “printing with laser printer” refers to a toner transfer printing process where toner is first printed on a transfer sheet and then transferred via lamination step to the pouch layer material.

[0028] The term “feature size” refers to structure features such as channel widths, channel-to-channel spacings, channel lengths, and inflatable chamber diameters, for example. Maximum feature size could be several meters for long snake robots.BK-2024-162-2-PCT -6-

[0029] It will be appreciated by those skilled in the art that the term printing as used herein is not limited to the specific embodiments described, but rather encompasses a broad range of printing and deposition techniques, including digital printing methods (e.g., inkjet, electrophotographic, laser, electrostatic, magnetographic, solid ink, thermal transfer, aerosol jet, nanoimprint) as well as analog printing methods (e.g., stencil / screen printing, flexography, gravure, offset lithography, letterpress, newspaper printing, and related processes), and any future-developed techniques capable of depositing material in a patterned or image wise manner.

[0030] Further aspects of the technology described herein will be brought out in the following portions of the specification, wherein the detailed description is for the purpose of fully disclosing preferred embodiments of the technology without placing limitations thereon.BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The technology described herein will be more fully understood by reference to the following drawings which are for illustrative purposes only:

[0032] FIG. 1 is a flow diagram of a toner transfer printing process and its integration as part of the pouch robot fabrication process according to one embodiment of the technology. Steps 1 through 4 demonstrate one toner transfer step: 1 ) lamination of LDPE, 2) printing toner on transfer paper, 3) transfer via lamination, and 4) removal of transfer paper. This sequence of steps is then repeated to create multiple layers of toner patterns sandwiched by LDPE layers.

[0033] FIG. 2 is a flow diagram of an ink jet printing process using solventbased inks and its integration as part of the pouch robot fabrication process according to one embodiment of the technology. For an n-layer pouch design made with n+1 film layers, the IMPRINT process comprises the following steps: 1 ) laminate 1 st LDPE film layer to semi-rigid base, creating temporary adhesion for ease of handling and alignment; 2) repeated steps of ink-jet printing the mth-layer pouch design, and laminating the m+1stlayer on top; 3) before adding the final layer, laser cutting small through-holes for pneumatic ports; 4) inkjet print the nth-layer pouch design; 5) laminate the n+1stfilm layerBK-2024-162-2-PCT -7-on top; 6) heat press for permanent fusing of all film layers; 7) laser cut outline of pouch robot to release; and 8) attach to rigid manifold and inflate.

[0034] FIG. 3 is a flow diagram of an alternative embodiment of the IMPRINT process that illustrates making fluidic connections between layers.

[0035] FIG. 4A and FIG. 4B are side sectional views of a three-layer pouch actuator with integrated links, made with four film layers (shaded regions) according to one embodiment of the presented technology. Unfused, inflatable regions are defined by printed ink (black regions). The middle, unbiased layer is used for structural links that connect between actuation pouches and is shown in the inflated and uninflated state. Actuation pouches are placed on the top and bottom layers to create bending motion. FIG. 4A shows the top, bottom, and middle actuation pouches in an uninflated state. FIG. 4B shows the top and bottom actuation pouches in an uninflated state and the middle actuation pouches in an inflated state.

[0036] FIG. 4C and FIG. 4D are side sectional views of the three-layer pouch actuator of FIG. 4A and FIG. 4B with the top inflated, the bottom uninflated, and the middle actuation pouches shown in the uninflated (FIG. 4C) and inflated (FIG. 4D) state.

[0037] FIG. 4E and FIG. 4F are side sectional views of the three-layer pouch actuator of FIG. 4A and FIG. 4B, with the top uninflated, the bottom inflated, and the middle actuation pouches shown in uninflated (FIG. 4E) and uninflated (FIG. 4F) states.

[0038] FIG. 5 is a top perspective exploded view of a bi-directional rectangular bending actuator. The same rectangular pouch design is used on Layer 1 and Layer 3 for differential, symmetric actuation. On layer 2, a series of connected cylinders is used to create low-inflated-profile, semi-rigid structural links in this embodiment. They have a slight overlap with actuation pouches above and below to avoid weak, un-inflated LDPE regions. By using inkjet- printed solvent ink to define pouch geometry, inflatable channels with widths as small as 0.3 mm are achieved.

[0039] FIG. 6 is a kinematic diagram of a 4-finger miniature dexterous hand, with two opposing pairs of 2-independent- DoF fingers. Joints with singleheaded arrows represent uni-directional bending actuators, and joints withBK-2024-162-2-PCT -8-double-headed arrows represent bi-directional bending actuators.

[0040] FIG. 7 is a schematic illustration of a continuum manipulator that comprises eight unidirectional rectangular bending actuators arranged in a row, such that adjacent actuators have alternating bending directions. All actuators are connected by constant-inflated structural links for added rigidity.

[0041] FIG. 8 is a schematic contextual view of an adjustable soft retractor device for surgical displacement of the cerebellum and target visualization according to one embodiment of the technology.

[0042] FIG. 9 is a schematic contextual view of a soft robot device for nerve / artery dissection according to one embodiment of the technology.

[0043] FIG. 10 is a schematic contextual view of a soft robot device for maxillary sinus visualization and biopsy according to one embodiment of the technology.

[0044] FIG. 11 is an illustrative printed pattern for layer 1 of the miniature dexterous hand shown kinematically in FIG. 6.

[0045] FIG. 12 is an illustrative printed pattern for layer 2 of the miniature dexterous hand shown kinematically in FIG. 6.

[0046] FIG. 13 is an illustrative printed pattern for layer 3 of the miniature dexterous hand shown kinematically in FIG. 6.

[0047] FIG. 14 is an illustrative printed pattern showing layers 1 , 2 and 3 of FIG. 11 through FIG. 13 combined into a 4-finger robotic configuration.DETAILED DESCRIPTION

[0048] Referring more specifically to the drawings, for illustrative purposes, devices and methods for pouch robot fabrication are generally shown. Several embodiments of the technology are described generally in FIG. 1 to FIG. 13 to illustrate the characteristics and functionality of the multi-layer inflatable thin-film pouch robots with many independent degrees of freedom and fabrication methods.

[0049] It will be appreciated that the methods may vary as to the specific steps and sequence, and the systems and devices may vary as to structural details without departing from the basic concepts as disclosed herein. The method steps are merely exemplary of the order that these steps may occur. TheBK-2024-162-2-PCT -9-steps may occur in any order that is desired, such that it still performs the goals of the claimed technology.

[0050] Referring now to FIG. 1 , an embodiment 10a of a method for pouch robot fabrication using toner transfer printing is generally illustrated. In the configuration of FIG. 1 , a semi-rigid build plate comprising a laminate of a Kapton™ substrate 12 with a middle Teflon™ layer 14 and a top layer of a thin thermoplastic film 16 such as Low-Density Polyethylene (LDPE) is prepared at step 1 a). The build plate can be temporarily laminated 18 at step 1 a) by roller lamination or any other suitable lamination technique.

[0051] At step 2a), toner powder 36a is printed onto a toner-receptive transfer sheet 20 in a selected toner pattern 22a using preset printer settings with a conventional laser printer. The printed transfer sheet 20 is then positioned such that the toner pattern 22a faces the thin film pouch (LDPE) layer 16 of the semi-rigid build plate and the toner pattern 22a is then transferred to the thin film 16 via heated lamination at step 3a).

[0052] At step 4a), the transfer sheet 20 is then separated from the build plate, leaving the toner pattern 22a affixed to the thin film layer 16, thereby defining a release layer pattern suitable for subsequent lamination and printing steps.

[0053] Step 1 a) through step 4a) demonstrate one toner transfer step: 1 a) lamination of LDPE, 2a) printing toner on transfer paper, 3a) transfer via lamination, and 4a) removal of transfer paper. This sequence of steps is then repeated to create multiple layers of toner patterns sandwiched by LDPE layers as shown in step 5a). Subsequent LDPE layers 16 can be added by lamination at 118 °C, for example, which creates a temporary bond between layers at step 5a). Before printing the pattern of the final layer, the layer stack is laser-machined to cut a group of small through-holes and enclosed by the final LDPE layer 16 that is laminated on top of the laminate to form an enclosed space 34 at step 5a). These enclosed through-holes 34 ultimately serve as pneumatic ports to external pressure sources.

[0054] At step 6a), the entire stack is then heat pressed 26 (e.g., 121 °C @ 413 kPa for 90 seconds) to produce a fused stack. Because the toner layers are thin compared to the thickness of the LDPE films, there is little height variation across each layer of the processed stack 28. The stack is optionallyBK-2024-162-2-PCT -10-trimmed at step 7a) and removed from the build plate. The enclosed space 34 can be oriented and coupled to a substrate 32 with a source of air at controllable pressures to form internal ducts as illustrated in step 8a).

[0055] Referring to FIG. 2, an alternative embodiment 10b of the process for pouch robot fabrication uses inkjet printing of solvent ink 36b. Like the embodiment shown in FIG. 1 , a composite base of a substrate 12 with a middle Teflon™ layer 14 and a top layer of a thin thermoplastic film 16 is produced at step 1 b). This base laminate of a film layer with a semi-rigid base creates a temporary adhesion layer for ease of handling and alignment. The build plate can be temporarily laminated at step 1 b) by roller lamination or any other suitable lamination technique.

[0056] At step 2b), the LDPE layer 16 is patterned with an ink pattern 22b using a solvent-based ink 36b dispensed by an inkjet printer. The process preferably uses solvent-based ink 36b as a blocking agent, which creates a masking layer such that pouch layers do not bond where ink is printed, and only bond where ink is absent. Compared to other inks such as UV-curable and water-based inks, solvent-based ink has good adhesion properties and a thin profile when dispensed on polymer film substrate. The ink 36b is then dispensed through a micro-piezo inkjet printer, which can realize complex and independent multi-layer pouch actuator designs at high resolution.

[0057] This process of step 2b) is repeated to provide a laminate with several patterned layers 16. Step 1 b) and step 2b) may then be repeated to create multiple layers of ink 36b patterns 22b sandwiched by LDPE layers 16. These subsequent LDPE layers 16 can be added by lamination at 118 °C, for example, which creates a temporary bond between layers.

[0058] Given an n-layer pouch design, the fabrication process builds a stack of n + 1 LDPE film layers, where the ink or toner patterns are printed on the top surface of the first n layers. FIG. 2 shows a schematic overview of fabricating a 3-layer pouch comprising four layers of LDPE, noting that the same process can be extended to more layers.

[0059] Before printing the pattern of the final layer at step 5b), the layer stack is laser-machined to cut a group of small through-holes 24 at step 3b). The final ink layer may be printed over the machined layer at step 4b), and theBK-2024-162-2-PCT -11-final LDPE layer 16 is then laminated on to the top of the stack at step 5b). This step forms an enclosed space 34 in the laminate as shown in step 5b).

[0060] At step 6b), the entire stack may be heat pressed (e.g., 121 °C @ 413 kPa for 90 seconds) to produce a fused stack. Because the printed ink layers 22b are thin compared to thickness of the LDPE films, little height variation is observed across each layer.

[0061] The processed stack is optionally trimmed at step 7b) and the processed laminate is then removed from the build plate. The enclosed spaces 34 of the laminate can be oriented and coupled to a substrate 32 that has a source of air at controllable pressures. The source has one or more internal ducts 38 that is fluidly coupled with the spaces 34 at step 8b) in this illustration.

[0062] The pouch robot fabrication process relies on depositing a release layer via printing. In this embodiment, solvent-ink is chosen as the separating layer, which is deposited by inkjet printing. This integrated fabrication embodiment advances the limit of thin-film soft pouch robots by combining inkjet printing and heat pressing. Prior methods, such as fusing with a pointed heat source or heat pressing with manually placed separator films, have been constrained to fabricating multi-layer pouches with similar layer designs. Thicker masking layers lead to large height variations per layer, resulting in incomplete fusing.

[0063] By inkjet printing a thin masking layer made of solvent ink, the fabrication process enables the creation of independent multi-layer pouch designs with small feature resolution and integrated pneumatic connections. Thus, this method allows for the simultaneous integration of pouch actuators, links, channels, and pneumatic ports in one process with sub-millimeter features.

[0064] Preferably, the patterned ink or toner materials have a contact angle of less than approximately 15 degrees with the polymer film where the pattern is deposited.

[0065] Referring now to FIG. 3 which is a flow diagram of an alternative embodiment 40 of the IMPRINT process that illustrates the fabrication of through holes and blind via holes using the fabrication processes shown inBK-2024-162-2-PCT -12-FIG. 1 or FIG. 2. More particularly, FIG. 3 illustrates fabricating a 3-layer pouch that comprises four layers of LDPE, but it will be noted that the same process can be extended to more layers. Unlike through holes which have holes that start below the top layer, and extend completely through all layers of thin film, used for connection to external pneumatic sources, blind via holes do not completely go through all layers of thin film, and are used for pneumatic connections for pouches on different layers. Blind via holes are necessary for multi-layer designs where interlayer connections can overlap other elements such as channels or pouches and allows higher density integration.

[0066] In the embodiment shown, at step 42 a base layer 0 is provided and through holes are laser cut according to a designed pattern. Typically, one through hole connection provides air to one pouch defined on a particular layer. Alternatively, for multiple pouches on different levels that can be controlled together, it is also possible to have the same through hole connect to multiple layers at once. Doing so simply requires the layer-cut through hole to go through an overlap in the pattern for multiple pouch layers.

[0067] At step 44, a print mask layer 1 is provided and a pattern is printed by an inkjet printer or laser printer. The fabrication process preferably uses solvent-based ink as a blocking agent, which creates a masking layer such that pouch layers do not bond where ink is printed, and only bond where ink is absent.

[0068] There are other classes of ink that could be substituted in place of solvent-based ink in the fabrication process, depending on the film material and processing temperatures. UV-curable inks, which cure instantly when exposed to UV light, can be used in place of solvent-based ink when fast drying of ink on film is needed, or for less environmental impacts. Waterbased inks including latex, pigment-based, and dye-based inks have limited adhesion to non-porous surfaces (such as plastic films) but could be advantageous if the film layers are porous, or if low levels of volatile organic compounds (VOCs) are required. Conventional laser printer toner materials can also be used to print the mask patterns.

[0069] At step 46, printed mask layer 1 is then laminated with layer 2 that mayBK-2024-162-2-PCT -13-also have a top surface that is printed with a pattern. At step 48, another printed layer (layer 3) is then laminated with the prior laminate of layer 1 and layer 2. This laminate of layer 1 , layer 2 and layer 3 can be repeated with different inkjet patterns.

[0070] At step 50, once the laminates are formed, through holes can be cut through or partially through the width of the structures. Then, at step 52, one or more hole masks can then be printed on to the top surface of layer 3.

[0071] In this embodiment, at step 54 the processed laminate is properly oriented on layer 0 so the through holes align on the bottom surface of layer 1 and a top film layer (layer 4) can be applied over layer 3 to seal the layers.

[0072] Given an n-layer pouch design, the IMPRINT process builds a stack of n + 1 LDPE film layers, where the ink patterns are printed on the top surface of the first n layers.

[0073] Note that after layer 3 is formed, holes are then cut through all three layers with a laser. As shown in step 52, or more hole masks can then be printed on to the top surface of layer 3. Then the final ink mask pattern is printed, and layer 4 is laminated on top. To achieve blind holes, another film layer without holes, layer 0, is laminated at the bottom of the stack. To achieve through holes, layer 0 is cut with a hole at the same position before laminating. In this embodiment, the processed laminate is accurately positioned on layer 0 so that the through holes align on the bottom surface of layer 1 and a top film layer (layer 4) is also applied over layer 3 to seal the layers. This process integrates the manufacturing of blind via holes with through holes, allowing them to be placed anywhere in the pouch design, simplifying pouch tubing, and allowing for more efficient pouch designs.

[0074] FIG. 3 also illustrates through-hole manufacturing on the left half, and blind via holes manufacturing on the right half. Both types of holes build layers 1 to 3 sequentially on one stack, printing ink mask pattern then laminating. Holes are then cut with a laser after layer 3, through all three layers. Then the final ink mask pattern is printed, and layer 4 is laminated on top. To achieve blind holes, another film layer without holes, layer 0, is laminated at the bottom of the stack, while for through holes, layer 0 is cut with a hole at the same position before laminating. This process integrates the manufacturing ofBK-2024-162-2-PCT -14-blind via holes with through holes, allowing them to be placed anywhere in the pouch design, simplifying pouch tubing, and allowing for more efficient pouch designs.

[0075] The fabrication methods that are shown in FIG. 1 , FIG. 2 and FIG. 3 have two main components: toner or inkjet printing to pattern film layers, and laminating / heat pressing for stacking film layers and permanent fusing. Due to their continuous nature, toner transfer, inkjet printing and laminating processes are easily implemented as roll-to-roll processing, making the pouch robot fabrication method suitable for roll-to-roll processing as well. This continuous processing technique allows for high throughput and scalability, making it ideal for mass production, as well as creating large scale pouch robots with small feature sizes.

[0076] To illustrate the general principles of the devices, a three-layer pouch actuator 60 with integrated links, made with four film layers (shaded regions) is shown in FIG. 4A through FIG. 4F. Unfused, inflatable regions are defined by printed ink (black regions). Actuation pouches are placed on the top and bottom layers to create bending motions. The middle, unbiased layer is used for structural links that connect between actuation pouches. FIG. 4A through FIG. 4F illustrates an example of a bidirectional bending actuator with integrated structural links. During use, the middle structural layer is inflated at constant pressure and bending in either direction is achieved by pressurizing the respective top or bottom pouch.

[0077] In FIG. 4A, the actuator 60 is shown with the top, bottom, and middle compartments uninflated. In FIG. 4B, the actuator 60 is shown with the left middle compartment 62 and the right middle compartment 64 inflated. As can be seen in FIG. 4B, actuator 60 remains generally planar when only the middle compartments are inflated.

[0078] In FIG. 4C, the middle compartments are uninflated but the top central compartment 66 is inflated thus causing a central bend with both sides moving upward from the plane. The same upward bending motion also occurs when the top central compartment 66 is inflated and the middle compartments 62, 64 are inflated as shown in FIG. 4D.

[0079] Similarly, in FIG. 4E, the middle compartments are uninflated but theBK-2024-162-2-PCT -15-bottom central compartment 68 is inflated thus causing a central bend with both sides moving downward from the plane of the device. The same downward bending motion also occurs when the bottom central compartment 68 and the middle compartments 62, 64 are inflated.

[0080] In the design option that is illustrated in FIG. 4A through FIG. 4F, the middle layer can be used as a stiffening component to connect between actuators. Alternatively, the middle layers 62, 64 can also be used as a stiffening component for the bending actuator itself. As seen in FIG. 4A through FIG. 4F, the biased middle layer (layer 2) can be designed to have multiple connected straight cylinders. When inflated, this middle layer design provides two advantages 1 ) increased stiffness of the bending actuator, and 2) faster deflation of bending actuators. Angular deflection profiles indicated that when the middle layer is inflated to a higher pressure, the range of the actuator decreases, suggesting an increase in the stiffness of the actuator, which is useful in reducing susceptibility to external disturbances and applications requiring load-bearing capacity.

[0081] Furthermore, with an inflated middle layer, the actuator was shown to return with a faster time constants for increasing middle layer pressures to their original positions compared to uninflated middle layer, which could be useful where faster actuator deflation is required.

[0082] Some embodiments of the current technology have a three-layer structure that can provide bi-directional actuation and two pouch layers, for example. This is analogous to a double-sided printed circuit board. Quad layer embodiments can provide three inflatable layers: pouch, middle layer fluid channels, and opposing pouch, for example. Structural links could be made with balanced inflated pouches, and channels can feed by the side of a structural link.

[0083] Turning now to FIG. 5, an exploded view of a four-layer, bi-directional actuator laminate 76 with a top surface layer 78 (Layer 4) and layers containing actuation pouches and stiffening structures. In this illustration of a bi-directional rectangular bending actuator 76, the same rectangular pouch design 90 is used on the base layer 88 (Layer 1 ) as the design 82 of the third layer 80 (Layer 3) for differential, symmetric actuation. On the second layerBK-2024-162-2-PCT -16-from the base layer 84 (Layer 2), a series of connected cylinders 86 is used to create low-inflated-profile, semi-rigid structural links. They have a slight overlap with actuation pouches 82, 90 above and below to avoid weak, uninflated LDPE regions.

[0084] For two independently controlled actuation pouches placed on the same layer, there is inevitably an uninflated thin-film region between the two pouches since they need to be disconnected. This uninflated region between two pouch actuators adds uncontrollable compliance, which increases the complexity of control. To solve this problem, an additional middle layer of inflated pouches is added to serve as structural links between pouch actuators as shown in FIG. 5. By incorporating a group of small cylinders connected in parallel, these pouches are designed to be unbiased and stiff when inflated while keeping a relatively low inflated profile. Structural link pouches may overlap at their ends with actuation pouches on a different layer, for secure connection while preserving independent degrees of freedom. When measured via a cantilever setup, a 9.3 mm by 11 .9 mm structural link pouch is found to have approximately four times the stiffness when inflated to maximum pressure (172 kPa), compared to the uninflated state.

[0085] Pouch actuators are typically designed to bend via anisotropic stiffness. For a pouch made of two relatively inextensible films with different stiffnesses, the side that is less stiff undergoes greater strain when pressurized, resulting in bending.

[0086] For the IMPRINT method, where n + 1 LDPE layers define n pouch layers, anisotropic stiffness may be achieved by placing actuation pouches at off-centered layers. The more off centered the pouch is placed, the greater the thickness difference between its two sides, and the greater the bending angle. For the case of four LDPE layers creating three pouch layers, actuation pouches are placed at either the 1st or 3rd pouch layer for uni-directional bending, or both for bidirectional bending shown in FIG. 4C through FIG. 4F. The middle unbiased layer is normally used for integrated structural links.

[0087] Accordingly, multi-layer inflatable pouches of any planar geometry can be created using thermal fusing, with inter-layer connections and a minimum feature resolution of about 0.3 mm. The multi-layer fabrication processBK-2024-162-2-PCT -17-enables the integration of pouches for bending actuation and structure, pneumatic channels, and external port connections. This high level of integration enables the fabrication of pouch robots with many independent DoFs.

[0088] Specific examples using four layers of 38 micrometer thick LDPE include 1 ) a 38 mm-wide 4-fingered robot hand with eight independent DoFs which rotates a cube within its palm and 2) a 138 mm-long planar continuum manipulator with ten independent DoFs for pick-and-place of a cylinder are illustrations. These example designs demonstrate the capability of ink- patterned masking to achieve new levels of functionality for thin-film pouch robots.

[0089] The technology described herein may be better understood with reference to the accompanying examples, which are intended for purposes of illustration only and should not be construed as in any sense limiting the scope of the technology described herein as defined in the claims appended hereto.

[0090] Example 1

[0091] To demonstrate the fabrication methods, a simple robot with inflatable features was designed, fabricated, and tested. A build plate made of semirigid and heat-resistant Kapton™ was selected and used to make it easier for manipulation and alignment of the laminates and structure. The build area was 172 mm by 172 mm, which is the maximum area of the heat press. To ensure the release of LDPE after fabrication, a layer of Teflon™ was attached to the build plate using a thermal adhesive. The LDPE layers were temporarily laminated on top of the Teflon™ layer using a hot roll laminator at 276 kPa and 118 °C.

[0092] An additional layer of Teflon™ was attached to the bottom side of the Kapton™ build plate using a hot mount adhesive to reduce the curvature of the build plate that may be induced by unbalanced residual strain in the LDPE layers. The solvent-based ink was printed onto the LDPE layers using a flatbed inkjet printer. Each layer can have its own unique inkjet-printed pattern for maximal design freedom. To maintain the planarity of pouch layers, subsequent LDPE layers are added by lamination at 118 °C, which creates aBK-2024-162-2-PCT -18-temporary bond between layers.

[0093] Before printing the pattern of the final layer of LDPE, the layer stack was laser-machined to cut a group of small through-holes at 40% power and 20% speed. These through-holes serve as pneumatic ports to external pressure sources. The pouch pattern of the last layer is printed, and 5) The final n + 1 LDPE layer was laminated on top.

[0094] Then, with the final LDPE layer laminated, a bench top press was used to permanently fuse all LDPE layers together at 121 °C and 413 kPa. A sheet of rubber was placed on the build assembly during heat pressing to ensure an even distribution of pressure. Because the ink layers were thin compared to thickness of the LDPE film, there was little height variation across each pouch layer, enabling complete fusing of layers both with independent layer designs and at much lower time compared to conventional heat press methods. Fabrication of one batch of four-layer pouch structures on the 172 mm by 172 mm build plate took approximately 24 minutes with a cost of $4.71 .

[0095] Finally, the actuator / robot was laser cut around the outline to release the design from the build plate. The pneumatic ports were connected to a rigid pneumatic manifold via double-sided adhesive with matching laser-cut holes, and the pouch robot was ready for connection to air pressure sources and operation.

[0096] The burst pressure of 1 -layer circular pouches made with two layers of LDPE film was measured. Circular pouches with diameters of 4 mm, 8 mm, and 16 mm burst and leak at 241 kPa, 172 kPa, and 124 kPa respectively. All leaks were due to tensile failure of LDPE under high pressure. The fused boundary remained intact for all pouches even after burst.

[0097] Three bending actuator types were implemented as base components for integrated pouch robots with the IMPRINT method using four 38 pm LDPE layers. A uni-directional bending pouch with a diamond-shaped sealed region was designed for large-angle one-directional bending with relatively high force. A bi-directional rectangular actuator, with two rectangular-shaped pouches for bending placed on 1st and 3rd layers, has the smallest footprint for smaller-angle bending. To achieve larger angle bending, multiple rectangular pouches can be connected. Two connected rectangles, namedBK-2024-162-2-PCT -19-“bidirectional compound,” for approximately double the bending range was demonstrated. All actuators were standardized to be the same width of 9.3 mm and fabricated with integrated structural links.

[0098] Example 2

[0099] To test the capability of the IMPRINT process for integrated fabrication of pouch systems with many independent degrees of freedom, a 4-finger miniature hand was designed and constructed with 4 LDPE film layers and demonstrated successful open-loop in-hand dexterous manipulation.

[0100] A kinematic diagram of the 4-finger miniature dexterous hand 92, with two opposing pairs of 2-independent-DoF fingers is shown schematically in FIG. 6. The miniature hand shown in FIG. 6 is designed with a non- anthropomorphic finger arrangement, with two opposing pairs of identical fingers in order to simplify finger control. Each finger of the hand 92 has identical fingertips 96, a bidirectional bending actuator 98, and a unidirectional bending actuator 100.

[0101] In this configuration, each finger 102 is coupled at one end to block 94 and controlled air source. A wide channel connecting the base and middle joints also provided link stiffness. A central channel for stiffening the distal actuator was connected to all fingers in common. Joints with single-headed arrows represent uni-directional bending actuators 100, and joints with double-headed arrows represent bi-directional bending actuators 98.

[0102] Example s

[0103] A second design example of the IMPRINT fabrication process was in the form of a soft continuum manipulator 104 with twelve control inputs and ten independently controllable DoFs, made from four LDPE film layers were fabricated and tested. A 12-input, 10-independent-DoF miniature planar continuum manipulator 104 was fabricated and mounted to a manifold 106 as shown kinematically in FIG. 7.

[0104] The robot manipulator 104 embodiment illustrated in FIG. 7 has three parts: an arm 108 with eight independent unidirectional actuators which provide in-plane bending motion (joints 1-8), a bidirectional wrist for adjusting orientation of the end-effector (joint 9), and a gripper 110 that grasps by wrapping around objects (joints a-f). In addition, constant-inflated structuralBK-2024-162-2-PCT -20-links connect each part of the manipulator, making the robot more closely resemble a rigid-link hyper-redundant manipulator. The robot 104 was trapezoidal-shaped, with a 10 mm-wide side and 42 mm-wide side. The length of the robot was 138 mm, with the movable parts measuring 86 mm.

[0105] The arm 108 of the manipulator 104 comprises eight unidirectional rectangular bending actuators arranged in a row, such that adjacent actuators have alternating bending directions (joints 1 -8 in FIG. 7). Joints with singleheaded arrows represent uni-bending actuators. Joints with double-headed arrows represent bi-directional bending actuators. The alternating actuator direction design of arm 108 was selected to give a more symmetric workspace than unidirectional actuators, which would only allow a curling-in motion. The bending actuators with the same direction are on the same layer, with independent tubing and pressure control for increased configuration space. All joints are connected by 5 mm-long constant inflation links in the middle unbiased layer, which had the same design as in FIG. 4A to FIG. 4E.

[0106] The manipulator arm 104 has eight bending DoF along its body for snake-like movement, implemented as eight independently controlled unidirectional rectangular actuators (joints 1 -8). The distal wrist is implemented by a bi-directional rectangular actuator (joint 9) allowing the gripper 110 to change direction independent of arm bending. The gripper 110 comprises six coupled unidirectional rectangular bending actuators (joints a-f), which together can bend approximately 300 degrees to wrap around an object. In addition, all actuators are connected by constant-inflated structural links for added rigidity.

[0107] The hyper-redundant degrees of freedom enable in-plane obstacle avoidance while maintaining orientation control. All bending actuators have the same out-of-plane rotation axis, thus limiting the pick-and-place to a 2D inplane operation. Like the hand robot of Example 2, the continuum manipulator is attached to a pneumatic manifold with adhesive tape. The manifold is positioned with a fixture such that the arm freely moves without contacting the table surface. Avoiding table contact eliminates external forces, other than minimal gravity loading from arm mass of 0.4 g.

[0108] In total, the manipulator has twelve independently controlled pressureBK-2024-162-2-PCT -21-channels: eight pressure regulated channels for the eight unidirectional bending actuators in the arm, and four on-off channels connected to 138 kPa for wrist, gripper, and structural link activation, respectively.

[0109] The layer patterns for the continuum manipulator 104 that were printed on each layer had several layers in this illustration. Layer 1 comprised 6 pneumatic ports, 6 air channels, and 4 bend-up rectangular actuators in the arm, 1 side of bidirectional rectangular actuator for the wrist, and the coupled compound bending actuator for the gripper. Layer 2 comprised one pneumatic port and the central structural links between the bending actuators. Layer 3 comprised 5 pneumatic ports, controlling 4 bend-down rectangular actuators in the arm and the opposite side of the bidirectional bending actuator in the wrist.

[0110] The continuum manipulator 104 was evaluated by using the device to pick up and place a 0.12 g cylindrical object with a diameter of 6 mm, a height of 20 mm, and a base of 12 mm. Assuming a quasi-static condition, an openloop control sequence was developed to move the cylinder. Before entering the sequence, the structural links were set to 172 kPa. The manipulator then follows the sequence: 1 ) bend toward the object with uni-directional bending actuators on one side of the manipulator (joints 2, 4, 6, 8) until the gripper touches the object, 2) grasp the object by closing the gripper (joints a-f), 3) move object to the middle, 4) place the object by turning off the gripper and engaging the wrist (joint 9) to separate from the object, 5) move away from the object with bending actuators on opposing side of the manipulator (joints 1 , 3, 5, 7), 6) fold the manipulator by bending the distal portion in the opposing direction using joint 6 and 8, reducing its effective length, 7) deflate the proximal bending actuators (joints 1 , 3) such that the manipulator moves toward the original position while avoiding collision with the object, and 8) move back to the original location as in step 1 ), ready for the next pick-and- place cycle. Overall, the controllability of the continuum soft manipulator has shown the capability of the IMPRINT process to integrate many degrees-of- freedom in a compact thin film robot.

[0111] Example 4

[0112] The methods enable the fabrication of soft pouch robots with greaterBK-2024-162-2-PCT -22-complexity (smaller feature size, and more connected layers). Through use of inflatable links, the robot structure (uninflated) will only be as thick as the product of the individual layer thickness and the number of layers. By increasing the number of joints compared to previous pouch robots, the robot can more easily reach locations in the body without being pushed around corners which risks damaging delicate tissue.

[0113] For example, the methods for producing devices with pouch actuators can be adapted to produce medical diagnostic and surgical devices. As shown in FIG. 8 manipulator devices can be adapted for use as an adjustable soft retractor 112. Surgeons performing a craniotomy 116 typically create an opening in the skull 114 to perform diagnostic imaging or surgical dissection procedures on the brain anatomy. For example, when tackling lesions around the cerebellum 122, surgeons may use fixed retractors to displace the cerebellum and visualize the target. In this setting, a soft retraction robot 118 can be fabricated that may include illuminating and imaging functions and can perform specific bending motions. As shown in FIG. 8, surgeons can conform 120 (e.g., by active bending to go around the cerebellum) the retractor robot 118 to the exact shape of the cerebellum. By doing so, it can retract the tissues at a desired site avoiding unnecessary tension on healthy tissue.

[0114] Similarly, the methods 124 can be used to design soft retractor robots 130 with conformations that can be used with artery 126 and nerve 128 separation or dissection. As shown in FIG. 9, soft retractor robots 130 can be used to produce a robot with conformations for treatment of trigeminal neuralgia, for example. Trigeminal neuralgia is a common condition causing intractable facial pain. This condition is caused by an artery compressing on the trigeminal nerve. The goal of surgery is to separate the compressing artery from the nerve. Often the artery is covered by the nerve and thus difficult to dissect and separate. The soft retractor robot 130 has an active band 132 that can actively bend around the nerve 128 and under the artery 126 and wrap 138 around the artery 126. In this embodiment, the distal tip 134 can have one or more integrated illumination LED’s, cameras, and working tool channels, for example. Because of the multiple bending points of this robot, it will be able to navigate around delicate structures, “grab” theBK-2024-162-2-PCT -23-artery 126 and separate 136 the artery (e.g., pull it way) from the nerve 126 without tension on the nerve or the artery.

[0115] Another soft robot 140 design illustration for performing a maxillary sinus biopsy procedure is shown in FIG. 10. The maxillary sinus is one of the paranasal sinuses and is commonly affected by pathology. The maxillary sinus has a maxillary sinus side 142 and a nasal cavity side 144. The maxillary sinus side 142 is connected to the nasal cavity via the maxillary ostium 146. The nasal cavity can be easily accessed through the nostrils, but accessing the maxillary sinus needs to be done under general anesthesia to remove its wall and access the cavity with rigid instruments. The soft retractor robot 148 is soft and capable of 270-degree active bending 152 through the maxillary ostium 146. The tip 150 of the robot 148 can have one or more integrated cameras, forward illumination lights, and working tool channels, for example.

[0116] As illustrated with the adaptations shown in FIG. 8, FIG. 9 and FIG. 10, the IMPRINT methods may be useful for fabricating pouch mechanisms beyond links and actuators. Pouches have been used to create pressure sensors, Quake-style pneumatic valves, and shape-changing surfaces, for example. The level of integration and scalability enabled by this method can enhance the functionality and complexity of these mechanisms. Moreover, the multi-layer capability of IMPRINT would allow any pouch-based mechanisms to be integrated together for more applications. For example, pouch sensors and valves could be combined with the links and joints demonstrated here to create thin-film soft pouch robots with integrated sensors, logic, and actuation. Overall, the fabrication processes increase accessibility to multi-layer soft pneumatic pouch systems, including soft pouch robots, with a high level of complexity, functionality, and size scalability.

[0117] Example s

[0118] The dexterous hand shown in FIG. 6 was designed with multiple layers and ink pattern designs on each layer of LDPE. The first printed layer pattern is illustrated in FIG. 11 . Layer 1 , 202, of this robot embodiment has four air channels 204, four pneumatic input / output ports 206, four anti-kink tubing segments 208, and four bidirectional compound bending actuators 210 forBK-2024-162-2-PCT -24-fingertips that are independently actuated.

[0119] Layer 2, 212, comprises one pneumatic port 214 that is connected to four central stiffening structural links (pouches) 216 that are coupled together. One embodiment of the patterned layer 2 is shown in FIG. 12.

[0120] Layer 3, 218, has a pattern of eight pneumatic ports 220, controlling the four bidirectional compound actuators 210 in the fingertips that complement the pouches on layer 2. Layer 3 also provides four coupled unidirectional diamond actuators 222 for finger links and four coupled unidirectional diamond actuators 224 for finger bases. The patterned layer 3 is illustrated in FIG. 13.

[0121] FIG. 14 shows the combination 226 of layer 1 , layer 2, layer 3 and a top layer with the three rotational axes 91 , 62, and 63 for each finger as illustrated for Finger 1 . FIG. 14 shows four fingers, Finger 1 through Finger 4.

[0122] In the diagram of FIG. 6, each finger 102 has a compliant compression axis and a tip rotation axis. For further simplification, a planar block palm 94 provides object support, thus the object manipulation is in-plane, and gravity is not a consideration except for block-palm friction.

[0123] Each finger is identical, using base joint (91 ) flexion to grasp, and the distal joint (93) abduction-adduction to provide object yaw motion in plane. The finger base flexion uses the unidirectional diamond pouch actuator and acts to control the grasp squeezing force.

[0124] To orient the distal link, the middle joint (92) uses a second unidirectional diamond pouch actuator which is driven in tandem with the base flexion joint. The distal abduction-adduction joint has two pouch layers and can be bidirectionally actuated with two pressure regulated channels.

[0125] In total, the hand has thirteen control ports available: eight channels for bidirectional abduction-adduction degrees of freedom, four channels for combined flexion and middle link orientation, and one common connection to each finger’s central channel. In operation, opposing fingers were driven jointly, thus six independent inputs were used for object reorientation.

[0126] The miniature hand 92 was driven in an open-loop with a basic sequence of commands to successively grasp the cube with one opposing pair of fingers 100, rotate the object by 90 degrees, then release the cubeBK-2024-162-2-PCT -25-(which rests on the palm) before the sequence repeats with the next pair of fingers.

[0127] The hand had thirteen independent pneumatic input channels.However, the common central stiffening channel was not used and opposing finger pairs were driven in tandem. Thus, each finger pair used only three channels: base flexion (01 / 02) and two channels for the bi-directional tip joint actuator (03), requiring six pressure regulator channels.

[0128] In operation, an open-loop set of pressure commands was given to the six pressure regulators and six steps were required for each 90° cube rotation, with 4 seconds per step to allow adequate time for pouch inflation and air venting. The pressure values were found empirically, with guidance from a simple kinematic simulation. For example, to make it easier to rotate the block in steps 2, 3, and 4, the base joint actuator pressure was reduced from 138 to 103 kPa.

[0129] From the description herein, it will be appreciated that the present disclosure encompasses multiple implementations of the technology which include, but are not limited to, the following:

[0130] A multilayer pouch robot device, comprising: a first layer of a first material; a first mask printed on the first layer, the first mask being a first pattern of ink or toner; and a second layer of a second material attached to the first layer at respective surfaces in contact so that regions with the first mask therebetween remain unattached to form at least one of a pouch, a fluid channel, or a separation between the first and second layers, wherein the first mask comprises minimum feature sizes greater than 0.1 mm and less than 5 mm.

[0131] The device of any previous or following implementation, further comprising: a second mask printed on the second layer, the second mask being a second ink or toner pattern; a third layer of a third material attached to the second layer at respective surfaces in contact so that regions with the second mask therebetween remain unattached to form at least one of a pouch, a fluid channel, or a separation between the second and third layers; wherein the multilayer pouch robot has an un-inflated thickness of preferably less than 300 pm, with thicker embodiments preferably less than 3 mm whichBK-2024-162-2-PCT -26-incorporate reinforcing elements such as rip-stop nylon.

[0132] The device of any previous or following implementation, further comprising: a second mask printed on the second layer, the second mask being a second ink or toner pattern; a third layer of a third material attached to the second layer at respective surfaces in contact so that regions with the second mask therebetween remain unattached to form at least one of a pouch, a fluid channel, or a separation between the second and third layers; a third mask printed on the third layer, the third mask being a third ink or toner pattern; and a fourth layer of a fourth material attached to the third layer at respective surfaces in contact so that regions with the third mask therebetween remain unattached to form at least one of a pouch, a fluid channel, or a separation between the third and fourth layers, wherein the multilayer pouch robot has an un-inflated thickness of less than 300 pm.

[0133] The device of any previous or following implementation, wherein the first layer of the first material is a first polymer film; wherein the second layer of the second material is a second polymer film; wherein the first ink pattern of the first mask comprises a first ink that has a contact angle less than 15 degrees with the first polymer film when deposited thereon; and wherein the first and second polymer films have melting temperatures that are lower than a melting temperature of the first ink.

[0134] The device of any previous or following implementation, wherein the first and second polymer films comprise thermoplastic polymer films.

[0135] The device of any previous or following implementation, wherein the thermoplastic polymer is selected from the group of a polyethylene (PE), a high-density PE, a low-density PE, polyethylene terephthalate (PET), Biaxially Oriented Polyethylene Terephthalate (BOPET), Polypropylene (PP), Biaxially Oriented Polypropylene (BOPP), Thermoplastic Elastomer (TPE), Thermoplastic Polyurethane (TPU), and combinations thereof.

[0136] The device of any previous or following implementation, wherein the first and second polymer layers are each less than 0.5 mm thick and greater than 0.005 mm thick, and wherein each the mask is less than 0.025 mm thick and greater than 0.0005 mm thick.

[0137] The device of any previous or following implementation, wherein theBK-2024-162-2-PCT -27-first and second polymer layers are each less than 0.2 mm thick and greater than 0.005 mm thick, and wherein each the mask is less than 0.01 mm thick and greater than 0.0005 mm thick.

[0138] The device of any previous or following implementation, wherein the first mask comprises minimum feature sizes greater than 0.1 mm and less than 1 mm.

[0139] The device of any previous or following implementation, further comprising: a controlled source of pressurized fluid fluidly coupled to the at least one of a pouch, a fluid channel, or a separation between layers.

[0140] A method of producing a multilayer pouch robot, the method comprising: (a) providing a first layer of a first material; (b) printing a first ink pattern onto the first layer to form a first mask for at least one of a pouch, a fluid channel, or a separation; (c) providing a second layer of a second material on the first layer; (d) printing a second ink pattern onto the second layer to form a second mask for at least one of a pouch, a fluid channel, or a separation; (e) repeating the providing layers of materials up to an nth layer of an nth material and printing an nth ink pattern on each the nth layer to form an nth mask for at least one of a pouch, a fluid channel, or a separation; (f) providing an (n+1 )th layer of an (n+1 )th material on the nth layer; and (g) heating and pressing the (n+1 ) layers to bond all layers of materials together while the n masks between adjacent layers prevents bonding to form the at least one of a pouch, a fluid channel, or a separation between every adjacent layer, (h) wherein n is an integer of at least 3.

[0141] The method of any previous or following implementation, wherein each layer is less than 0.5 mm thick, and wherein each the mask is less than 0.025 mm thick.

[0142] The method of any previous or following implementation, wherein each layer is greater than 0.005 mm thick and less than 0.2 mm thick, and wherein each the mask is less than 0.01 mm thick.

[0143] The method of any previous or following implementation, wherein n is at least 4 and less than 25.

[0144] The method of any previous or following implementation, further comprising: providing a substrate coated with a release layer prior to theBK-2024-162-2-PCT -28-providing the first layer of the first polymer film; and attaching the first layer of the first polymer film to the release layer to be held flat during subsequent production steps.

[0145] The method of any previous or following implementation, further comprising releasing the pouch robot from the release layer.

[0146] The method of any previous or following implementation, further comprising cutting at least one via hole through one or more of the n polymer layers configured to form a fluid connection to at least one pouch or the fluid channel region.

[0147] The method of any previous or following implementation, further comprising attaching a fluid manifold to at least one of the first layer of polymer film or the (n+1 )th polymer film; and forming a fluid connection between the fluid manifold and the at least one via hole.

[0148] The method of any previous or following implementation, further comprising controlling a flow of fluid through the fluid connection of each via hole.

[0149] A pouch robot, comprising: a first layer of a first polymer film having a first actuator mask and a corresponding fluid channel mask printed thereon; a second layer of a second polymer film disposed on the first layer, the second layer having a structural link mask and corresponding fluid channel mask printed thereon and arranged offset from the actuator mask to be on at least one side thereof, the first and second layers of polymer films together form a first fluidly activatable actuator; a third layer of a third polymer film disposed on the second layer, the third layer having a second actuator mask and corresponding fluid channel mask printed thereon and arranged to be above the first actuator mask, the second and third layers of polymer films together form a fluid activatable structural link; and a fourth layer of a fourth polymer film disposed on the third layer, the third and fourth layers of polymer films together form a second fluidly activatable actuator, wherein the first, second, third and fourth layers of polymer films are heat bonded together, wherein each of the first and second actuators are fluidly addressable to provide a selectable bi-directional bending actuator, and wherein the structural link is fluidly addressable to provide a selectable structural link.BK-2024-162-2-PCT -29-

[0150] The method of any previous or following implementation, wherein each layer essentially comprises a same polymer material, and each ink pattern and corresponding mask essentially comprises the same ink or toner material.

[0151] The method of any previous or following implementation where the cutting of the via hole is with one of laser drilling, knife cutting, melting, or a punch.

[0152] The method of any previous or following implementation where the cutting of the multilayer pouch robot is through one of laser cutting, knife cutting, or die cutting.

[0153] The method of any previous or following implementation, wherein all of the printing to form the n masks is ink-jet printing or laser printing.

[0154] The method of any previous or following implementation, further comprising cutting a multilayer pouch robot from the bonded (n+1 ) bonded layers.

[0155] As used herein, the term "implementation" is intended to include, without limitation, embodiments, examples, or other forms of practicing the technology described herein.

[0156] As used herein, the singular terms "a," "an," and "the" may include plural referents unless the context clearly dictates otherwise. Reference to an object in the singular is not intended to mean "one and only one" unless explicitly so stated, but rather "one or more."

[0157] Phrasing constructs, such as “A, B and / or C,” within the present disclosure describe where either A, B, or C can be present, or any combination of items A, B and C. Phrasing constructs indicating, such as “at least one of” followed by listing a group of elements, indicates that at least one of these groups of elements is present, which includes any possible combination of the listed elements as applicable.

[0158] References in this disclosure referring to “an embodiment,” “at least one embodiment” or similar embodiment wording indicates that a particular feature, structure, or characteristic described in connection with a described embodiment is included in at least one embodiment of the present disclosure. Thus, these various embodiment phrases are not necessarily all referring to the same embodiment, or to a specific embodiment which differs from all theBK-2024-162-2-PCT -30-other embodiments being described. The embodiment phrasing should be construed to mean that the particular features, structures, or characteristics of a given embodiment may be combined in any suitable manner in one or more embodiments of the disclosed apparatus, system, or method.

[0159] As used herein, the term "set" refers to a collection of one or more objects. Thus, for example, a set of objects can include a single object or multiple objects.

[0160] Relational terms such as first and second, top and bottom, upper and lower, left and right, and the like, may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0161] The terms "comprises," "comprising," "has", "having," "includes", "including," "contains", "containing" or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, apparatus, or system, that comprises, has, includes, or contains a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, apparatus, or system. An element proceeded by "comprises . . . a", "has . . . a", "includes . . . a", "contains . . . a" does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, apparatus, or system, that comprises, has, includes, contains the element.

[0162] As used herein, the terms "approximately", "approximate,” “substantially", "substantial", "essentially", and "about", or any other version thereof, are used to describe and account for small variations. When used in conjunction with an event or circumstance, the terms can refer to instances in which the event or circumstance occurs precisely as well as instances in which the event or circumstance occurs to a close approximation. When used in conjunction with a numerical value, the terms can refer to a range of variation of less than or equal to ± 10% of that numerical value, such as less than or equal to ±5%, less than or equal to ±4%, less than or equal to ±3%, less than or equal to ±2%, less than or equal to ±1 %, less than or equal to ±0.5%, less than or equal to ±0.1 %, or less than or equal to ±0.05%. ForBK-2024-162-2-PCT -31-example, "substantially" aligned can refer to a range of angular variation of less than or equal to ±10°, such as less than or equal to ±5°, less than or equal to ±4°, less than or equal to ±3°, less than or equal to ±2°, less than or equal to ±1 °, less than or equal to ±0.5°, less than or equal to ±0.1 °, or less than or equal to ±0.05°.

[0163] Additionally, amounts, ratios, and other numerical values may sometimes be presented herein in a range format. It is to be understood that such range format is used for convenience and brevity and should be understood flexibly to include numerical values explicitly specified as limits of a range, but also to include all individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly specified. For example, a ratio in the range of about 1 to about 200 should be understood to include the explicitly recited limits of about 1 and about 200, but also to include individual ratios such as about 2, about 3, and about 4, and sub-ranges such as about 10 to about 50, about 20 to about 100, and so forth.

[0164] The term "coupled" as used herein is defined as connected, although not necessarily directly and not necessarily mechanically. A device or structure that is "configured" in a certain way is configured in at least that way but may also be configured in ways that are not listed.

[0165] Benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or element of the technology described herein or any or all the claims.

[0166] In addition, in the foregoing disclosure various features may be grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Inventive subject matter can lie in less than all features of a single disclosed embodiment.

[0167] The abstract of the disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaningBK-2024-162-2-PCT -32-of the claims.

[0168] It will be appreciated that the practice of some jurisdictions may require deletion of one or more portions of the disclosure after the application is filed. Accordingly, the reader should consult the application as filed for the original content of the disclosure. Any deletion of content of the disclosure should not be construed as a disclaimer, forfeiture, or dedication to the public of any subject matter of the application as originally filed.

[0169] All text in a drawing figure is hereby incorporated into the disclosure and is to be treated as part of the written description of the drawing figure.

[0170] The following claims are hereby incorporated into the disclosure, with each claim standing on its own as a separately claimed subject matter.

[0171] Although the description herein contains many details, these should not be construed as limiting the scope of the disclosure, but as merely providing illustrations of some of the presently preferred embodiments. Therefore, it will be appreciated that the scope of the disclosure fully encompasses other embodiments which may become obvious to those skilled in the art.

[0172] All structural and functional equivalents to the elements of the disclosed embodiments that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed as a "means plus function" element unless the element is expressly recited using the phrase "means for". No claim element herein is to be construed as a "step plus function" element unless the element is expressly recited using the phrase "step for".BK-2024-162-2-PCT -33-

Claims

CLAIMSWhat is claimed:1 . A multilayer pouch robot device, comprising: a first layer of a first material; a first mask printed on said first layer, said first mask being a first pattern of ink or toner; and a second layer of a second material attached to said first layer at respective surfaces in contact so that regions with said first mask therebetween remain unattached to form at least one of a pouch, a fluid channel, or a separation between said first and second layers, wherein said first mask comprises minimum feature sizes greater than 0.1 mm and less than 5 mm.

2. The device of claim 1 , further comprising: a second mask printed on said second layer, said second mask being a second ink or toner pattern; a third layer of a third material attached to said second layer at respective surfaces in contact so that regions with said second mask therebetween remain unattached to form at least one of a pouch, a fluid channel, or a separation between said second and third layers; wherein said multilayer pouch robot has an un-inflated thickness of less than 300 pm.

3. The device of claim 1 , further comprising: a second mask printed on said second layer, said second mask being a second ink or toner pattern; a third layer of a third material attached to said second layer at respective surfaces in contact so that regions with said second mask therebetween remain unattached to form at least one of a pouch, a fluid channel, or a separation between said second and third layers;BK-2024-162-2-PCT -34-a third mask printed on said third layer, said third mask being a third ink or toner pattern; and a fourth layer of a fourth material attached to said third layer at respective surfaces in contact so that regions with said third mask therebetween remain unattached to form at least one of a pouch, a fluid channel, or a separation between said third and fourth layers, wherein said multilayer pouch robot has an un-inflated thickness of less than 300 pm.

4. The device of claim 1 , wherein said first layer of said first material is a first polymer film; wherein said second layer of said second material is a second polymer film; wherein said first ink pattern of said first mask comprises a first ink that has a contact angle less than 15 degrees with said first polymer film when deposited thereon; and wherein said first and second polymer films have melting temperatures that are lower than a melting temperature of said first ink.

5. The device of claim 4, wherein said first and second polymer films comprise thermoplastic polymer films.

6. The device of claim 5, wherein said thermoplastic polymer is selected from the group of a polyethylene (PE), a high-density PE, a low-density PE, polyethylene terephthalate (PET), Biaxially Oriented Polyethylene Terephthalate (BOPET), Polypropylene (PP), Biaxially Oriented Polypropylene (BOPP), Thermoplastic Elastomer (TPE), Thermoplastic Polyurethane (TPU), and combinations thereof.

7. The device of claim 4, wherein said first and second polymer layers are each less than 0.5 mm thick and greater than 0.005 mm thick, and wherein each said mask is less than 0.025 mm thick and greater than 0.0005 mm thick.BK-2024-162-2-PCT -35-8. The device of claim 7, wherein said first and second polymer layers are each less than 0.2 mm thick and greater than 0.005 mm thick, and wherein each said mask is less than 0.01 mm thick and greater than 0.0005 mm thick.

9. The device of claim 1 , wherein said first mask comprises minimum feature sizes greater than 0.1 mm and less than 1 mm.

10. The device of claim 1 , further comprising: a controlled source of pressurized fluid fluidly coupled to said at least one of a pouch, a fluid channel, or a separation between layers.

11. A method of producing a multilayer pouch robot, the method comprising:(a) providing a first layer of a first material;(b) printing a first ink pattern onto said first layer to form a first mask for at least one of a pouch, a fluid channel, or a separation;(c) providing a second layer of a second material on said first layer;(d) printing a second ink pattern onto said second layer to form a second mask for at least one of a pouch, a fluid channel, or a separation;(e) repeating said providing layers of materials up to an nth layer of an nth material and printing an nth ink pattern on each said nth layer to form an nth mask for at least one of a pouch, a fluid channel, or a separation;(f) providing an (n+1 )th layer of an (n+1 )th material on said nth layer; and(g) heating and pressing said (n+1 ) layers to bond all layers of materials together while said n masks between adjacent layers prevents bonding to form said at least one of a pouch, a fluid channel, or a separation between every adjacent layer,(h) wherein n is an integer of at least 3.

12. The method of claim 11 , wherein each said layer is less than 0.5 mm thick, and wherein each said mask is less than 0.025 mm thick.BK-2024-162-2-PCT -36-13. The method of claim 12, wherein each said layer is greater than 0.005 mm thick and less than 0.2 mm thick, and wherein each said mask is less than 0.01 mm thick.

14. The method of claim 11 , wherein n is at least 4 and less than 25.

15. The method of claim 11 , further comprising: providing a substrate coated with a release layer prior to said providing said first layer of said first polymer film; and attaching said first layer of said first polymer film to said release layer to be held flat during subsequent production steps.

16. The method of claim 15, further comprising releasing said pouch robot from said release layer.

17. The method of claim 11 , further comprising: cutting at least one via hole through one or more of the n polymer layers configured to form a fluid connection to at least one of said pouch or said fluid channel region.

18. The method of claim 17, further comprising: attaching a fluid manifold to at least one of said first layer of polymer film or said (n+1 )th polymer film; and forming a fluid connection between said fluid manifold and said at least one via hole.

19. The method of claim 18, further comprising: controlling a flow of fluid through said fluid connection of each via hole.

20. A pouch robot, comprising: a first layer of a first polymer film having a first actuator mask and a corresponding fluid channel mask printed thereon;BK-2024-162-2-PCT -37-a second layer of a second polymer film disposed on said first layer, said second layer having a structural link mask and corresponding fluid channel mask printed thereon and arranged offset from said actuator mask to be on at least one side thereof, said first and second layers of polymer films together form a first fluidly activatable actuator; a third layer of a third polymer film disposed on said second layer, said third layer having a second actuator mask and corresponding fluid channel mask printed thereon and arranged to be above said first actuator mask, said second and third layers of polymer films together form a fluid activatable structural link; and a fourth layer of a fourth polymer film disposed on said third layer, said third and fourth layers of polymer films together form a second fluidly activatable actuator, wherein said first, second, third and fourth layers of polymer films are heat bonded together, wherein each of said first and second actuators are fluidly addressable to provide a selectable bi-directional bending actuator, and wherein said structural link is fluidly addressable to provide a selectable structural link.BK-2024-162-2-PCT -38-

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