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<p>Tensegrity-based strain sensing offers a lightweight and mechanically stable alternative to conventional sensors that typically operate within narrow deformation limits. In this study, we investigate a self-responsive tensegrity module capable of reliably sensing large deformations in the range of approximately 0–10% module strain, supported by both experiments and mechanics-based modeling. A three-stage icosahedral tensegrity structure is fabricated using fused deposition modeling and subjected to compression tests, while its mechanical response is analyzed using a reduced-order model based on the principle of virtual work (PVW) and a complementary finite element analysis (FEA) in Abaqus. The hyperelastic behavior of thermoplastic polyurethane (TPU) strings is characterized via uniaxial tensile tests and captured using a two-parameter Mooney–Rivlin model, whereas conductive-coated strings enable indirect strain measurement through resistance changes during deformation. A mechanics–electrical coupling framework is established by combining (i) a PVW-based axial force model for the tensegrity members and (ii) a sheet-resistance kinematic model for the conductive coating. Resistance-derived member forces are then compared against PVW predictions and in the initial deformation regime. After accounting for an initial pretension-settling phase, the experimental and simulated load–strain responses exhibit close agreement up to ~ 10% strain, and resistance-based force estimates show consistent trends with PVW predictions for most monitored strings. These findings demonstrate that tensegrity architectures can function as lightweight, structurally integrated strain/force transducers over an extended deformation range, and they provide a mechanistic foundation for tensegrity-based sensing modules in soft robotics, proprioceptive mechanisms, and multifunctional mechanical architectures.</p>

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Design and Characterization of a Tensegrity-based Strain Sensor for Large Deformations

  • 期刊论文

  • 发表日期：

    2026年8月5日

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  • Yunjeong Kim,
  • Nasu Kim,
  • Namjung Kim

摘要

Tensegrity-based strain sensing offers a lightweight and mechanically stable alternative to conventional sensors that typically operate within narrow deformation limits. In this study, we investigate a self-responsive tensegrity module capable of reliably sensing large deformations in the range of approximately 0–10% module strain, supported by both experiments and mechanics-based modeling. A three-stage icosahedral tensegrity structure is fabricated using fused deposition modeling and subjected to compression tests, while its mechanical response is analyzed using a reduced-order model based on the principle of virtual work (PVW) and a complementary finite element analysis (FEA) in Abaqus. The hyperelastic behavior of thermoplastic polyurethane (TPU) strings is characterized via uniaxial tensile tests and captured using a two-parameter Mooney–Rivlin model, whereas conductive-coated strings enable indirect strain measurement through resistance changes during deformation. A mechanics–electrical coupling framework is established by combining (i) a PVW-based axial force model for the tensegrity members and (ii) a sheet-resistance kinematic model for the conductive coating. Resistance-derived member forces are then compared against PVW predictions and in the initial deformation regime. After accounting for an initial pretension-settling phase, the experimental and simulated load–strain responses exhibit close agreement up to ~ 10% strain, and resistance-based force estimates show consistent trends with PVW predictions for most monitored strings. These findings demonstrate that tensegrity architectures can function as lightweight, structurally integrated strain/force transducers over an extended deformation range, and they provide a mechanistic foundation for tensegrity-based sensing modules in soft robotics, proprioceptive mechanisms, and multifunctional mechanical architectures.