Robotics continues to draw inspiration from nature, researchers at EPFL’s CREATE lab have unveiled a striking innovation: a fully 3D-printed elephant robot that mimics the musculoskeletal structure of its biological counterpart. But this isn’t just a charming replication—it’s a breakthrough in how variable stiffness and complex movements can be achieved using a single material and a novel lattice-based design method.
Single Material, Infinite Possibilities
Traditionally, replicating the complex combination of soft tissues and rigid bones requires multiple materials or intricate assemblies. The CREATE lab, led by Professor Josie Hughes, sidestepped that limitation entirely. Their approach uses just one material, yet achieves varying levels of stiffness and flexibility through a computational lattice design that adjusts both geometry and material distribution.
The result? A lightweight structure that can transition seamlessly from soft and deformable to stiff and load-bearing, depending on the design of the internal lattice. This technique empowers engineers to fine-tune mechanical properties within a single 3D print job—no multi-material extrusion, post-processing, or adhesives needed.
Bioinspired Engineering in Action
To demonstrate this principle, the EPFL team created a robot modeled after an elephant, a creature known for its combination of strength and dexterity. The robot’s trunk showcases the material’s ability to bend and twist like muscular tissue, while its legs and joints exhibit the rigidity necessary to support movement and weight.
This isn’t just about visual mimicry. Each part of the robot is mechanically functional, with performance tailored through computational design. The structure can replicate actions like walking or grasping, offering a glimpse into future robots that are both versatile and structurally efficient.
A Blueprint for the Future of Soft Robotics
The implications of this work extend well beyond animal replicas. By combining bioinspiration with advanced 3D printing and a single elastic material, EPFL’s technique could streamline the development of soft robots, wearable devices, and next-generation prosthetics.
The project also opens doors to greater design freedom. Engineers can focus on function and form simultaneously, adjusting stiffness not by swapping materials, but by varying lattice parameters—an elegant solution that mirrors the complexity of living systems.
EPFL’s elephant robot isn’t just a feat of creative engineering—it’s a milestone in additive manufacturing. Through innovative use of lattice structures and computational design, the CREATE lab is redefining what’s possible with soft robotics, unlocking new pathways for devices that are strong, agile, and adaptive—all without ever changing the material.
