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Design and Experimental Validation of a 3D Printed Torsional Series Elastic Actuator for Safe Human Robot Interaction

arXiv · AI, language, vision and robotics · article · Sep 16, 2026 · UTC

Ensuring intrinsic safety in physical human robot interaction (pHRI) is a critical requirement for social and service robots. While Series Elastic Actuators (SEAs) offer hardware based compliance, traditional metallic designs often require complex, multi part assemblies. This paper presents the design, finite element analysis (FEA), and experimental validation of a low stiffness, torsional spring for SEAs, manufactured via 3D printed thermoplastic polyurethane (TPU). The compliant element exhibits a highly linear torque deformation response (Ks = 0.066 Nm/degree), matching numerical prediction

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