Climbing robots can investigate scientifically valuable sites that conventional rovers cannot access due to steep terrain features. Robots equipped with microspine grippers are particularly well-suited to ascending rocky cliff faces, but most existing designs are either large and slow or limited to relatively flat surfaces such as walls. We present a novel free-climbing robot to bridge this gap through innovations in gripper design and force control. Fully passive grippers and wrist joints allow secure grasping while reducing mass and complexity. Forces are distributed among the robot’s grippers using an optimization-based control strategy to minimize the risk of unexpected detachment. The robot prototype has demonstrated vertical climbing on both flat cinder block walls and uneven rock surfaces in full Earth gravity.

Microspine grippers allow robots to ascend steep rocky slopes and cliff faces, enabling scientific exploration of exposed strata on Earth and other solar system bodies. Historically, the Shape Deposition Manufacturing (SDM) process has been used to fabricate multi-material suspensions for load-sharing among multiple microspines. We instead apply the Hybrid Deposition Manufacturing (HDM) process to microspine fabrication, and we further propose a novel 3D-printed microspine suspension design that can be manufactured via Fused Deposition Manufacturing (FDM) alone, using a single flexible material with an embedded fishhook. We use a model of microspine stiffness that allows designers to compensate for order-of-magnitude changes in material tensile modulus by adjusting geometric parameters of the design. The stiffness model and the FDM microspine design are validated through tensile testing, and mechanical properties of the HDM and FDM designs are compared against a standard SDM microspine design. We demonstrate that the FDM process can produce microspines with equivalent normal and axial stiffness and superior maximum load and fatigue response to SDM microspines, and discuss additional advantages of the FDM process for rapid prototyping and broader accessibility.

Aircraft that can launch ballistically and convert to autonomous, free-flying drones have applications in many areas such as emergency response, defense, and space exploration, where they can gather critical situational data using onboard sensors. This paper presents a ballistically-launched, autonomously-stabilizing multirotor prototype (SQUID - Streamlined Quick Unfolding Investigation Drone) with an onboard sensor suite, autonomy pipeline, and passive aerodynamic stability. We demonstrate autonomous transition from passive to vision-based, active stabilization, confirming the multirotor's ability to autonomously stabilize after a ballistic launch in a GPS-denied environment.

The operation of multirotors in crowded environments requires a highly reliable takeoff method, as failures during takeoff can damage more valuable assets nearby. The addition of a ballistic launch system imposes a deterministic path for the multirotor to prevent collisions with its environment, as well as increases the multirotor's range of operation and allows deployment from an unsteady platform. In addition, outfitting planetary rovers or entry vehicles with such deployable multirotors has the potential to greatly extend the data collection capabilities of a mission. A proof-of-concept multirotor aircraft has been developed, capable of transitioning from a ballistic launch configuration to a fully controllable flight configuration in midair after launch. The transition is accomplished via passive unfolding of the multirotor arms, triggered by a nichrome burn wire release mechanism. The design is 3D printable, launches from a three-inch diameter barrel, and has sufficient thrust to carry a significant payload. The system has been fabricated and field tested from a moving vehicle up to 50mph to successfully demonstrate the feasibility of the concept and experimentally validate the design's aerodynamic stability and deployment reliability. SUPPLEMENTARY MATERIAL Videos of the experiments: https://youtu.be/sQuKJfllyRM.