Dual‐Chamber One‐Step Molding Actuator with Straight‐Curved Crease Prismatic Design for Large‐Range Motions and Structural Stability

Soft actuators are gaining attention for their exceptional deformability and adaptability to meet the diverse demands of practical soft robotics applications. However, soft actuators with pneumatic actuation often struggle to simultaneously achieve large-range motions and structural stability. Addressing this challenge, a dual-chamber straight-curved crease origami prismatic (SCOP) actuator is proposed that introduces anisotropic stiffness through origami-inspired straight-curved creases and a foldable partition, enabling multidimensional motions including elongation and contraction, with an axial displacement reaching 106.7% of the actuator's original length (elongation 51.1% and contraction 55.6%), over 160° bidirectional bending, and a 209% increase in structural stability compared to curve crease bellows. The actuator is fabricated through one-step molding using a single material, and its principles, modeling, and design are systematically analyzed. The versatility and feasibility of the SCOP actuator are validated through its integrations into a wearable assistive device, a soft gripper, and a single-actuator crawling robot, which leverage various combinations of the SCOP's actuation modes to meet diverse motion requirements. This design provides a high-performance and practical solution for soft robotic systems requiring large-range, multidirectional motions with enhanced strength and reliability.