Propulsive Force Characterization of a Bio-Robotic Sea Lion Foreflipper: A Kinematic Basis for Agile Propulsion

Unmanned underwater vehicles (UUVs) capable of agile, high-speed maneuvering in complex environments require propulsion systems that can dynamically modulate three-dimensional forces. The California sea lion (<i>Zalophus californianus</i>) provides an exceptional biological model, using its foreflippers to achieve rapid turns and powerful propulsion. However, the specific kinematic mechanisms that govern instantaneous force generation from its powerful foreflippers remain poorly quantified. This study experimentally characterizes the time-varying thrust and lift produced by a bio-robotic sea lion foreflipper to determine how flipper twist, sweep, and phase overlap modulate propulsive forces. A three-degree-of-freedom bio-robotic flipper with a simplified, low-aspect-ratio planform and single compliant hinge was tested in a circulating flow tank, executing parameterized power and paddle strokes in both isolated and combined-phase trials. The time-resolved force data reveal that the propulsive stroke functions as a tunable hybrid system. The power phase acts as a force-vectoring mechanism, where the flipper's twist angle reorients the resultant vector: thrust is maximized in a broad, robust range peaking near 45°, while lift increases monotonically to 90°. The paddle phase operates as a flow-insensitive, geometrically driven thruster, where twist angle (0° optimal) regulates thrust by altering the presented surface area. In the full stroke, a temporal-phase overlap governs thrust augmentation, while the power-phase twist provides robust steering control. Within the tested inertial flow regime (Re ≈ 10⁴-10⁵), this control map is highly consistent with propulsion dominated by geometric momentum redirection and impulse timing, rather than circulation-based lift. These findings establish a practical, experimentally derived control map linking kinematic inputs to propulsive force vectors, providing a foundation for the design and control of agile, bio-inspired underwater vehicles.