A compliant metastructure design with reconfigurability up to six degrees of freedom

Compliant mechanisms with reconfigurable degrees of freedom are gaining attention in the development of kinesthetic haptic devices, robotic systems, and mechanical metamaterials. However, available devices exhibit limited programmability and form-customizability, restricting their versatility. To address this gap, we propose a metastructure concept featuring reconfigurable motional freedom and tunable stiffness, adaptable to various form factors and applications. These devices incorporate passive flexures and actively stiffness-changing rods to modify kinematic freedom. A rational design pipeline informs the flexures’ topological arrangements, geometric parameters, and control signals based on targeted mobilities, enabling the creation of unitary joints with up to six degrees of freedom. Our demonstrative application examples include a wrist device that has an effective stiffness of 0.370 Nm/deg (unlocked state, 5% displacement) to 2.278 Nm/deg (locked state, 1% displacement) to enable dynamic joint mobility control, a haptic thimble device (2.27-52.815 Nmm−1 at 1% displacement) that mimics the sensation of touching physical materials ranging from soft gel to metal surfaces, and a wearable device composed of multiple joints tailored for the arm and hand to augment haptic experiences or facilitate muscle training. We believe the presented method can help democratize compliant metastructures development and expand their versatility for broader contexts.