Computational design of ultra-robust strain sensors for soft robot perception and autonomy

Compliant strain sensors are crucial for soft robots’ perception and autonomy. However, their deformable bodies and dynamic actuation pose challenges in predictive sensor manufacturing and long-term robustness. This necessitates accurate sensor modelling and well-controlled sensor structural changes under strain. Here, we present a computational sensor design featuring a programmed crack array within micro-crumples strategy. By controlling the user-defined structure, the sensing performance becomes highly tunable and can be accurately modelled by physical models. Moreover, they maintain robust responsiveness under various demanding conditions including noise interruptions (50% strain), intermittent cyclic loadings (100,000 cycles), and dynamic frequencies (0–23 Hz), satisfying soft robots of diverse scaling from macro to micro. Finally, machine intelligence is applied to a sensor-integrated origami robot, enabling robotic trajectory prediction (<4% error) and topographical altitude awareness (<10% error). This strategy holds promise for advancing soft robotic capabilities in exploration, rescue operations, and swarming behaviors in complex environments.