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Soft pneumatic actuators have become indispensable for many robotic applications due to their reliability, safety, and design flexibility. However, the currently available actuator designs can be challenging to fabricate, requiring labor-intensive and time-consuming processes like reinforcing fiber wrapping and elastomer curing. To address this issue, we propose to use simple-to-fabricate kirigami skins—plastic sleeves with carefully arranged slit cuts—to construct pneumatic actuators with pre-programmable motion capabilities. Such kirigami skin, wrapped outside a cylindrical balloon, can transform the volumetric expansion from pneumatic pressure into anisotropic stretching and shearing, creating a combination of axial extension and twisting in the actuator. Moreover, the kirigami skin exhibits out-of-plane buckling near the slit cut, which enables high stretchability. To capture such complex deformations, we formulate and experimentally validates a new kinematics model to uncover the linkage between the kirigami cutting pattern design and the actuator’s motion characteristics. This model uses a virtual fold and rigid-facet assumption to simplify the motion analysis without sacrificing accuracy. Moreover, we tested the pressure-stroke performance and elastoplastic behaviors of the kirigami-skinned actuator to establish an operation protocol for repeatable performance. Analytical and experimental parametric analysis shows that one can effectively pre-program the actuator’s motion performance, with considerable freedom, simply by adjusting the angle and length of the slit cuts. The results of this study can establish the design and analysis framework for a new family of kirigami-skinned pneumatic actuators for many robotic applications. 

Soft pneumatic actuators have found many applications in robotics and adaptive structures. Traditionally, these actuators are constructed by wrapping layers of reinforcing helical fibers around an elastomeric tube. This approach is versatile and robust, but it suffers from a critical disadvantage: cumbersome fabrication procedures. Wrapping long helical filaments around a cylindrical tube requires expensive equipment or excessive manual labor. To address this issue, we propose a new approach towards designing and constructing pneumatic actuators by exploiting the principle of kirigami, the ancient art of paper cutting. More specifically, we use “kirigami skins” — plastic sleeves with carefully arranged slit cuts — to replace the reinforcing helical fibers. This paper presents an initial investigation on a set of linear extension actuators featuring kirigami skins with a uniform array of cross-shaped, orthogonal cuts. When under internal pressurization, the rectangular-shaped facets defined by these cuts can rotate and induce the desired extension motion. Through extensive experiments, we analyze the elastic and plastic deformations of these kirigami skins alone under tension. The results show strongly nonlinear behaviors involving both in-plane facet rotation the out-of-plane buckling. Such a deformation pattern offers valuable insights into the actuator’s performance under pressure. Moreover, both the deformation characteristics and actuation performance are “programmable” by tailoring the cut geometry. This study lays down the foundation for constructing more capable Kirigami-skinned soft actuators that can achieve sophisticated motions.