This semester our class assembled the control board from the Soft Robotics tool Kit, a system for testing pnuematic actuators. After printing out their sample file for a mold of an actuator on the Object printer, casting it in rubber and testing it successfully, we began designing one of our own.
Soft Robotics toolkit website
Our project is to make a sandal with actuating straps that start flat and inflate to grip your feet. We are close, but still working out some issues to make the sandals move properly.

For our first test, we modeled and printed the mold on the object printer. The the sizing and spacing of the chambers and walls of the actuator were based off of the measurements of this Soft Robotic Gripper. While one strap curled as we injected air into it, the other side didn’t, and with the side that worked, the connecting chamber seemed to be over inflating, and the individual mini chambers weren’t inflating enough.
We decided to switch from 3d printing the molds, to milling them out of HDPE for cheaper, faster molds. We also designed three separate test straps with slight variations on the actuator shape and size as well as the chamber size and spacing.
Our first round of tests all failed because the paper (which was probably cut too big) prevented the two halves of the molds from bonding, and each test blow out almost instantly upon the air being applied.

For our second round, we used a form of synthetic silk in place of the paper. We wanted something that was rigid enough to prevent the actuator from bending on one side and that the rubber could more easily bond to. Above is a photo of the recently poured dragon skin rubber in one of our test molds with the piece of silk layed on top of the shallow side of the mold. By restricting the bend on one side, it encourages the other to curl in a controlled manner.
This second round still had a few problems like chamber clogging and air holes around the seem.
We made some more modifications to the design and decided to cast the tubing into the molds, since inserting the tubing at the end proved to be problematic.

An image of our sandal mold being milled on the CNC router in a sheet of HDPE.

Setting up the tubing. We’ve been using small amounts of water based clay in our molds to secure the tubing. The tubing is slightly too thick for the entrance points of the actuators.

Us mixing the rubber.

We used a degassing chamber to remove many of the bubbles within the rubber which could affect the air flow. We experimented with dragon skin rubber with different curing times. The faster curing rubber seemed to work the best.



We added valves to the shoes to regulate the air flow so that the actuator could fill up and then be plugged to stay inflated in position. We milled the sole of the sole to be bonded with the top piece that contains the actuators.


