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Abstract This research presents a novel design of a four-bar mechanism featuring a variable stiffness link (VSL) as the output component, aimed at enabling diverse end-effector trajectories without modifying the link length or moment input. By employing both single-beam and multi-section beam configurations within a large deflection model, the study investigates the effect of varying link stiffness under constant load and geometric conditions on the mechanism’s trajectory outcomes. The proposed design was validated through both numerical modeling and experimental testing of a built prototype. The findings confirm the prototype’s alignment with theoretical predictions, highlighting the VSL’s key role in significantly enhancing the adaptability and application range of four-bar mechanisms. This advancement circumvents the traditional constraints of fixed-trajectory mechanisms, proposing a versatile, efficient, and cost-effective solution for complex motion applications in compliant mechanism design.