Lego-Like Stiffness Configuration of Planar Compliant Modules for Task-Specific Flexible Interfaces

Abstract

Compliant mechanisms provide compact and intrinsic structural compliance for regulating physical interactions between mechanisms and environments. However, different tasks demand distinct stiffness characteristics, often requiring task-specific optimization and redesign due to limited geometric design space and inherent coupling among multiple stiffness components. This paper presents a Lego-like stiffness configuration approach using stackable planar compliant modules. Three complementary module geometries are introduced, with their stiffness characteristics further regulated through beam width, plate thickness, and module orientation. A unified stiffness model is established for quantitative analysis of individual and composed modules. Further, a two-stage optimization method is presented to achieve desired stiffness profiles, combining a genetic algorithm for configuration and sequential quadratic programming for parameter refinement. Experimental verification shows deviations below 6.5% for simulated stiffness. A flexible wrist is further developed as a representative implementation, exhibiting distinct compliant and dynamic responses under different stiffness characteristics. An optimized modular composition realizes prescribed stiffness values and maintains compliant obstacle interaction during high-speed motion at 1 m/s, with a maximum tested angular compliance of approximately $15^\circ$. The proposed framework provides a systematic approach for constructing flexible interfaces with task-specific stiffness characteristics.