Optimization of a tetrahedron compliant spherical joint via computer-aided engineering tools

This article focuses on enhancing the range of motion (ROM) of the Tetra II joint, a spherical compliant joint consisting of three internally interconnected tetrahedron-shaped elements that achieve motion through elastic deformation. Despite its excellent precision, this specific design is constrained in terms of ROM due to internal contacts among the tetrahedral elements. To overcome this limitation, this study utilizes a computer-aided engineering (CAE) framework to optimize the configuration of the Tetra II joint and enhance its ROM. The resultant optimized joint, referred to as Tetra III, is subsequently compared to Tetra II in terms of both ROM and center shift. Finite element models (FEM) are employed to validate the optimization results and examine how various tetrahedron-shaped geometries impact the joint’s performance. The newly optimized joint exhibits a significantly higher ROM compared to the previous version, while maintaining excellent precision and overall smaller dimensions. Finally, to demonstrate its manufacturability, the Tetra III joint is produced using selective laser sintering (SLS) technology, with Duraform PA serving as the construction material. The successful fabrication serves as a demonstrative example of the improved design of the Tetra III joint.