Twisting Soft Sleeve Actuator: Design and Experimental Evaluation

Soft wearable actuators must align with anatomical joints, conform to limb geometry, and operate at low pneumatic pressures. Yet most twisting mechanisms rely on bulky attachment interfaces and relatively high actuation pressures, limiting practicality in assistive applications. This study introduces the first Twisting Soft Sleeve Actuator (TSSA), a self-contained, wearable actuator that produces controlled bidirectional torsion. The design integrates helically folded bellows with internal stabilization layers to suppress radial expansion and enhance torque transmission. The TSSA is fabricated from thermoplastic polyurethane using a Bowden-type fused filament fabrication (FFF) process optimized for airtightness and flexibility. Performance was characterized using a modular test platform that measured angular displacement and output force under positive pressure (up to 75 kPa) and vacuum (down to −85 kPa). A parametric study evaluated the effects of fold width, fold angle, wall thickness, and twist angle. Results demonstrate bidirectional, self-restoring torsion with clockwise rotation of approximately 30 degrees and a peak output force of about 40 N at 75 kPa, while reverse torsional motion occurred under vacuum actuation. The TSSA enables anatomically compatible, low-pressure torsion, supporting scalable, multi-degree-of-freedom sleeve systems for wearable robotics and rehabilitation.