Design and Characterization of a Variable-Length Continuum Mechanism with Force Locking

Abstract: The utility of flexible continuum mechanisms for dexterous navigation is often impaired by their low stiffness, making them ineffective at manipulation in high-force scenarios. To address this challenge, we propose a novel continuum mechanism that achieves both flexible and rigid behavior by antagonistic extension and contraction of a rod-driven continuum helical structure. The helical design combines variable-length capacity with force locking for workspace and stiffness enhancement. In this article, we present the detailed design of the proposed mechanism and characterize its performance through experiments that quantify bending and stiffness. The results demonstrate 180 degree bending range of motion with an average distal positioning error of <10%. Further tests demonstrate that force locking directly improves axial stiffness and thus indirectly increases bending stiffness anisotropically, with maximum bending stiffness along load paths with a large axial component. Tensioning the driving rods provides additional stiffness tunability in the force-locked state, where increasing rod tension proportionally increases bending stiffness with a dimensionless gain of 0.56.