Kinematic precision scaling with physical errors in miniaturization of four-bar polymer compliant machines

A precision-scaling kinematic model with the effects of physical error is investigated in the miniaturization of four-bar polymer machines with compliant joints. A pseudolinkages model (PLM) for the multiple-links compliant machine is formulated. A scaling formulation of the multiple-links compliant machine and its associated PLM is developed. A method for scaled-up test and scaled-down analysis of the compliant mechanism with the considerations of physical errors of fabrication processes, material properties, and experimental tests is proposed. By defining an index of signal-to-noise ratio, the performance of the miniature realization under physical errors is evaluated. The applications of the scaling PLM for the miniature realization of a compliant machine are illustrated by performing both numerical analysis and experimental testing on four-bar compliant polyethylene machines.