Versatile Pneumatic Twisted Coiled Actuators Enabled by Fiber‐Polymer Composite Fabrication

ABSTRACT Soft pneumatic actuators are attractive for robotics due to their speed, force capacity, and material simplicity, yet their performance is difficult to tune because the actuation mechanism is typically tightly coupled to the fabrication method. We present a manufacturing and modeling approach for fiber polymer composite pneumatic twisted coiled actuators (PTCAs) that decouples these constraints and enables precise encoding of actuation behavior. The resulting actuators achieve rapid (<0.1 s) contraction, low‐pressure operation (<80 psi), large contractile strain (>80%), forces up to 20 N, and efficiencies near 50%. A mechanical model captures the dominant deformation mechanics and accurately predicts actuation behavior across diverse designs, allowing systematic exploration of how PTCA geometry and fiber orientation influence twisting, force transmission, and strain amplification. We demonstrate the versatility of this platform with a chameleon‐tongue–inspired PTCA system and a durable integrated module that lifts its pump, batteries, electronics, and additional weight for over 10,000 cycles. This framework provides tunable, scalable artificial muscles for soft robotic applications.