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<p>This study presents the design, fabrication, and experimental validation of a 3D-printed microgripper based on a compliant mechanism. Compliant mechanisms offer significant advantages over traditional rigid-body designs, including reduced component count, enhanced precision, and improved reliability. The microgripper is designed using SOLIDWORKS and optimized through finite element analysis (FEA) simulations to achieve optimal gripping force and displacement. The structure incorporates flexure hinges and is fabricated using Polyethylene terephthalate glycol (PETG) carbon fiber, a biocompatible and lightweight material. Actuation is achieved using Shape Memory Alloy (SMA) wires, enabling efficient and controlled motion. Static structural and modal analyses were conducted to evaluate the mechanical behavior, while experimental testing validated the numerical predictions. The numerical analysis estimated a maximum displacement of 0.349&#xa0;mm and a gripping force of 3.2&#xa0;N, while experimental results measured 0.365&#xa0;mm and 3.35&#xa0;N, yielding deviations of 4.5% and 4.7%, respectively. This study introduces the use of PETG–carbon-fibre composite in SMA-actuated compliant microgrippers, offering enhanced stiffness, reduced fabrication cost, and close numerical–experimental correlation (4.5% deviation). The close agreement between numerical and experimental findings validates the accuracy of the design and confirms its potential for high-precision applications. These findings demonstrate the accuracy of the numerical approach in predicting the microgripper performance. This work introduces a novel PETG–carbon-fibre compliant structure with optimized flexure geometry and validated numerical–experimental correlation, offering superior stiffness, cost-efficiency, and actuation accuracy compared to existing SMA-driven grippers. The study underscores the potential of integrating 3D printing and compliant mechanisms for precision micromanipulation in biomedical engineering, micro-robotics, and micro-assembly.</p>

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Design, fabrication and performance evaluation of a 3D-printed microgripper based on compliant mechanisms for precision manipulation

  • 期刊论文

  • 发表日期：

    2026年1月26日

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  • V. Gopal,
  • R. Bharanidaran,
  • S. Jesudass Thomas,
  • G. Ashwin Prabhu

摘要

This study presents the design, fabrication, and experimental validation of a 3D-printed microgripper based on a compliant mechanism. Compliant mechanisms offer significant advantages over traditional rigid-body designs, including reduced component count, enhanced precision, and improved reliability. The microgripper is designed using SOLIDWORKS and optimized through finite element analysis (FEA) simulations to achieve optimal gripping force and displacement. The structure incorporates flexure hinges and is fabricated using Polyethylene terephthalate glycol (PETG) carbon fiber, a biocompatible and lightweight material. Actuation is achieved using Shape Memory Alloy (SMA) wires, enabling efficient and controlled motion. Static structural and modal analyses were conducted to evaluate the mechanical behavior, while experimental testing validated the numerical predictions. The numerical analysis estimated a maximum displacement of 0.349 mm and a gripping force of 3.2 N, while experimental results measured 0.365 mm and 3.35 N, yielding deviations of 4.5% and 4.7%, respectively. This study introduces the use of PETG–carbon-fibre composite in SMA-actuated compliant microgrippers, offering enhanced stiffness, reduced fabrication cost, and close numerical–experimental correlation (4.5% deviation). The close agreement between numerical and experimental findings validates the accuracy of the design and confirms its potential for high-precision applications. These findings demonstrate the accuracy of the numerical approach in predicting the microgripper performance. This work introduces a novel PETG–carbon-fibre compliant structure with optimized flexure geometry and validated numerical–experimental correlation, offering superior stiffness, cost-efficiency, and actuation accuracy compared to existing SMA-driven grippers. The study underscores the potential of integrating 3D printing and compliant mechanisms for precision micromanipulation in biomedical engineering, micro-robotics, and micro-assembly.