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ABSTRACT Most animals can successfully travel across cluttered, uneven environments and cope with enormous changes in surface friction, deformability and stability. However, the mechanisms used to achieve such remarkable adaptability and robustness are not fully understood. Even more limited is the understanding of how soft, deformable animals such as tobacco hornworm Manduca sexta (caterpillars) can control their movements as they navigate surfaces that have varying stiffness and are oriented at different angles. To fill this gap, we analyzed the stepping patterns of caterpillars crawling on two different types of substrate (stiff and soft) and in three different orientations (horizontal and upward/downward vertical). Our results show that caterpillars adopt different stepping patterns (i.e. different sequences of transition between the swing and stance phases of prolegs in different body segments) based on substrate stiffness and orientation. These changes in stepping pattern occur more frequently in the upward vertical orientation. The results of this study suggest that caterpillars can detect differences in the material properties of the substrate on which they crawl and adjust their behavior to match those properties. 

Summary A design and manufacturing method is described for creating a motor tendon–actuated soft foam robot. The method uses a castable, light, and easily compressible open-cell polyurethane foam, producing a structure capable of large (~70% strain) deformations while requiring low torques to operate ( < 0.2 N·m). The soft robot can change shape, by compressing and folding, allowing for complex locomotion with only two actuators. Achievable motions include forward locomotion at 13 mm/s (4.3% of body length per second), turning at 9◦/s, and end-over-end flipping. Hard components, such as motors, are loosely sutured into cavities after molding. This reduces unwanted stiffening of the soft body. This work is the first demonstration of a soft open-cell foam robot locomoting with motor tendon actuators. The manufacturing method is rapid (~30 min per mold), inexpensive (under $3 per robot for the structural foam), and flexible, and will allow a variety of soft foam robotic devices to be produced.