In the world of robot fabrication, the dream of manufacturing machines ready to go directly off the line is still many years away, or at least it was. A team of Researchers at the University of California recently stunned the market after releasing details of a new fabrication method and robot design that requires no electricity and is ready to go right off the printer. Here’s what you need to know about 3D printed robots.
How Are Robots Made? Exploring Modern Robot Fabrication Techniques
There are a lot of different types of robots and even more ways to create these devices. Traditional robots can be built on assembly lines and may require a lot of steps to assemble and get going. For example, you may have one manufacturer produce the body, while others produce electronic components, batteries, controllers, and other core components.
What Are Soft Robots? Benefits and Real-World Uses
Soft robots are another type of machine that does away with the rigid exoskeleton found in traditional robots. Instead, soft robots utilize alternative materials like silicones and designs that allow them to alter their shape. The main benefits of soft robots are that they support manipulation, can traverse complex environments, and provide safe interaction with humans.
Advancements in 3D Printing Soft Robots with Fluidic Circuits
The demand for soft robots has led to several manufacturing process upgrades. Recent breakthroughs in 3D printing have enabled engineers to design soft robots that are more capable in a single run. Today’s most advanced soft robot fabrication methods decrease the complexity of soft robots.
To accomplish this task, pneumatic circuits that leverage nonlinear material responses are used. The use of fluidic control circuits enables engineers to manufacture more devices at a single location. Notably, the engineers of this project were also pivotal in other works, including creating a 3D-printed robotic gripper and crawler with embedded control circuits.
Challenges in 3D Printing and Assembling Soft Robots
There are a lot of problems still facing the soft robotics manufacturing sector. For one, cast molding systems allow for the creation of parts, but controlling the units still requires additional components. Also, it’s expensive, labor-intensive, and not readily available to most people.
In many instances, a complex system of pumps, valves, and other electronics must be connected to the body on a separate board via wires to achieve any form of controlled locomotion. The need to have the boot tethered eliminates its benefits and limits its soft robot capabilities, such as navigating tight spaces or environments.
New Study Unveils Fully 3D-Printed, Electronics-Free Walking Robot
The study “Monolithic Desktop Digital Fabrication of Autonomous Walking Robots,”1 published in the journal Advanced Intelligent Systems, highlights how engineers developed a fully 3D-printed, electronics-free, six-legged robot that can walk immediately after printing. Even more impressive is the fact that the device is powered solely by a constant air pressure source.
The study is revolutionary for multiple reasons. For one, it explains in detail how the engineers are able to overcome the challenges of 3D printing a closed valve. In the report, the team successfully achieves off-the-printer robot locomotion utilizing symmetric oscillation via air-powered phase delay valves.
How Desktop 3D Printers Enable Fully Functional Soft Robots
Notably, the engineers used an off-the-shelf, commercially available 3D desktop printer to create soft components with complex geometries that require minimal human labor. The engineers research several materials. They even went as far as to partner with the BASF corporation via its California Research Alliance (CARA) to test which materials worked best to create the frame, artificial muscles, and a control system of the team’s six-legged robot.
Source UC San Diego
A 3D-Printed Walking Robot That Works Right Off the Printer
The walking robot the team printed is capable of walking on its own without any electronic components. Instead, it relies on compressed air and a network of valves that open and close based on pressure changes to move its six legs. Notably, the team’s creation can traverse rough terrain, untethered, using only a compressed gas cartridge as a power source.
Robot Legs
One of the unique aspects of the off-the-shelf robot is its leg design. The six legs were printed utilizing commercially available 3D-printing filament. Each of the legs integrates soft, printable, antagonistic pneumatic actuators. This setup provides each expenditure with four degrees of motion. Each leg can move up, down, forward, and backward.
To create a walking action, the legs need to be connected to some form of pressurized air or fluid. Under constant pressure, one set of legs will bend down, lifting the body higher and helping the bot to clear rough terrain. At the same time, another set of legs will raise slightly. From there, the final set of legs bends downward and towards the back to create a forward pushing action. This causes the front legs to then bend downwards, completing a step cycle.
Soft Actuators
Notably, the device can accomplish this task thanks to the integration of embedded fluidic circuits in the body of the robot. Printing these devices was more difficult than you would imagine. The engineers had to place considerable effort into determining the best method to print these airtight components like actuators, valves, and sensors.
Pneumatic Oscillating Circuit
At the core of this next-generation soft robot design is a printable fluidic oscillator circuit. This circuit generates four cyclic output pressure signals, which are vital. Impressively, the engineers created it to accomplish this task using only a single pressure input.
They determined that a monolithic 3D-printable four-phase bistable oscillating valve was the best solution. Their custom-built oscillating valve integrates six states in one working cycle. To accomplish this task, it utilizes the mechanical motions of the inner membranes and valve channels to manipulate thresholds, creating state changes due to gradual pressure changes.
Each valve directs air flow to the next stage of the process when pressure limits are reached. Interestingly, when questioned on how the team came up with this concept, they replied that the design was inspired by early locomotive steam engines.
How Durable Is a 3D-Printed Robot? Test Results Revealed
The lab testing phase of the soft robot began with an open-air monitoring process. In this step, the robot was lifted, and air pressure was applied. The team then noted the exact actions the robot made and how they would affect motion if the robot were on the ground. After recording the motions of the legs in the air, the team was able to adjust the design to create a distinct walking pattern.
The next test was to see how the robot functioned on only air pressure. The team tested the electronics-free operation of the robot using a 16-g CO2 cartridge with a mechanical regulator set to 20 psi. They noted that they could get approximately 80 seconds of operation from this setup.
Lifetime Test
Next, durability was tested via lifecycles. The team focused on testing a single valve to get the most detail. As part of the test, constant pressure was applied and its effects registered. They noted that the oscillating valve functioned for 19,809 cycles before it completely failed.
3D-Printed Robots Test Results
The lab test revealed some impressive results. For one, the robot created by the team could traverse a wide array of terrain. The bot successfully crossed turf, sand, and various other difficult terrains, including underwater.
Interestingly, the robot walked 85cm in 21 seconds at 4cm a second during its smooth surface trials. The testing revealed that the lifting action of the legs were in the first sequence of its step helped the bot to gain enough lift to travel through rough environments.
The durability test shows that the devices can function nonstop for three days straight. Additionally, the team discovered that the main weak point of the design is the four membranes in the oscillating valve. This discovery wasn’t a huge surprise as these are the components that endure the most air pressure, repeated force, and deflection within the system.
Benefits of 3D Printing Soft Robots with No Electronics
There are multiple benefits that the 3D printed robots study provides. For one, these devices can be printed using a regular desktop 3D solution. This approach means that these units are readily accessible to the average person or business. They are ready off the printer and require no human interaction or post-print clean up to be operational.
Why 3D-Printed Robots Without Electronics Are a Game Changer
Definitely one of the coolest aspects of the project is the decision to eliminate the need for electronics. The ability for these boots to operate without electronics means that they are the obvious solution for environments that are not electronics-friendly.
Scientific studies into space, or around high radiation or magnetic locations, are a prime example of where these devices would come in handy. Additionally, underwater environments have always been troublesome for traditional electronics due to high-pressure constraints.
Low-Cost Robotics: How 3D Printing Is Making Robots Cheaper
This study opens the door for the printing of super-low-cost robots. The device that the team engineers created cost around $20. While this may only be able to walk, future designs could help you accomplish core tasks without kicking up your electricity bill or fabrication costs.
3D-Printed Robots: Real-World Uses and When to Expect Them
There are several applications for electronics-free robots. These devices could be sent in to conduct important surveillance of hostile or dangerous areas. The advantage of this approach is that a printer could be dropped on location and robots created on site. This strategy would allow for easier transportation.
The data contained in the soft robots study could lead to the rapid deployment of low-cost, resilient units in environments where traditional electronics fail, such as areas with strong radiation, disaster zones, or even other planets. Given the simplicity and affordability of the design, practical applications could emerge within the next 3 to 5 years.
Meet the Team Behind the Electronics-Free 3D-Printed Robot
The 3D printed robot study was hosted at the University of California, San Diego. The lead authors include Yichen Zhai, Jiayao Yan, and Michael T. Tolley. The paper also lists Albert De Boer, Martin Faber, Rohini Gupta, and the BASF California Research Alliance as contributing to the work. Additionally, the study was partially funded by the National Science Foundation.
Notably, this team has been pivotal in the development of soft robotic technology. The group introduced an electronics-free robotic gripper in 2022. This experience helped them to create the next generation of electronics-free devices. Now, their goal is to find ways to move the compressed gas storage internally and research more biodegradable materials.
Top Companies Advancing 3D Printing and Soft Robotics
The use of robots in the home and business is on the rise. As such, there is strong demand to dominate this market. Notably, the robotics and 3D printing markets have a lot of key players. These firms have poured billions into R&D to create functioning next-gen devices. Here’s one company that continues to innovate and deliver.
3D Systems Corporation (DDD -2.56%) entered the market in 1986 and is based in California. Its initial goal was to offer next-generation 3D printing services to commercial clientele. As a pioneer in 3D printing, the firm was pivotal in prototyping and other critical components for the aerospace, automotive, healthcare, entertainment, and industrial markets.
3D Systems Corporation (DDD -2.56%)
Today, 3D Systems is at the forefront of advancing additive manufacturing technologies, including applications in robotics. The company has +1,925 employees and reported $488M in revenue in 2023. Additionally, the company inked a strategic partnership with Daimler Buses to provide local 3D printers that can create spare parts.
Latest on 3D Systems Corp.
3D-Printed Robots
These advancements represent another step forward in the evolution of soft robotics. By eliminating the need for electronics and enabling full functionality straight off a desktop 3D printer, this research paves the way for affordable, resilient, and deployable machines in environments where traditional robots fall short. As development continues, the potential applications—from disaster relief to space exploration—are vast and inspiring. A strong salute to these engineers for their hard work and efforts that could alter the course of the robotics industry moving forward.
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Studies Referenced:
1. Zhai, Y., Yan, J., De Boer, A., Faber, M., Gupta, R., & Tolley, M. T. (2025). Monolithic desktop digital fabrication of autonomous walking robots. Advanced Intelligent Systems. https://doi.org/10.1002/aisy.202400876