Enhancement of EAP Actuated Facial Expressions by

Designed Chamber Geometry in Elastomers

Hanson D. a, Bergs R. b, Tadesse Y. b, White V.a, Priya S. b
a
Hanson Robotics Inc, 6117 Reiger Avenue, Dallas, TX 75214
b
Automation and Robotics Research Institute, UTA, Ft Worth, TX 76118

ABSTRACT
In this paper, the authors explore various ways that designed chambering of elastomers can enhance electroactive
polymer (EAP) actuation. Such enhancements include structuring of chambers for various mechanical functions and
advantages, boosting of surface area of a polymer for enhanced ionic migration, construction of advanced electret foams
for sensing and for tunable hydrophobicity for micro/pumping action, and distribution of composite EAP devices
throughout the chambered elastomer to achieve discrete controllability of electroactive polymer actuators. The authors
also discuss the chambering of EAP materials themselves for enhanced actuation effects.
With varied design of the chambers of the elastomer, the mechanical and structural properties of the elastomer
can be tuned to greatly enhance EAP actuation. The chambers can be designed in accordion-like bellows to achieve
extreme elongation with low forces, in spiral geometries to effect negative or neutral poisson’s ratio under actuation, and
with embedded fluidic bellows for fluidic actuation or sensing. These are but a few examples of the advantages that can
be achieved via designed chambering of elastomers.
The authors also discuss various application uses of the described chambering technologies. Such chambered
elastomers, combined with advanced muscle-like actuators, can substantially benefit facelike robots (useful for
entertainment and education etc), prosthetics, and numerous modalities of bio-inspired locomotion. In the efforts of the
authors to generate facial expression robots with low-power lightweight actuators is described.

Keywords: EAP, chambered, enhanced actuation, Humanoid robot, artificial muscle, face chart matrix.

1.0 INTRODUCTION
The characteristics of Electro-actuated polymers (EAP) are typically considered inadequate for applications in robotics.
But in recent years, there has been both dramatic increases in EAP technological capbilities and reductions in power
requirements for actuating bio-inspired robotics. As the two trends continue to converge, one may anticipate that
dramatic breakthroughs in biologically inspired robotic actuation will result due to the marraige of these technologies.
To demonstrate this concept of a platform to accelerate this convergence, the authors will discuss their work in
the niche application of robotic facial expression. In particular, expressive robots appear to be within the range of EAP
actuation, thanks to their low force requirements. An Albert Einstein robot will be presented, demonstrating realistic
expressions with dramatically decreased force requirements.
Bio-inspired robots must interact with the world by physical motion. To this end, EAP actuators promise many
benefits over existing actuation technologies like electromagnetic gear-motors. EAP actuators may be mechanically
simpler, fundamentally linear in their actuation, and similar to biological muscle in their visco-elastic dampening and
resonant characteristics [Bar-Cohen, 2004]. Moreover, EAP actuators promise to be potentially lower in cost relative to
today’s common actuators.
Yet, even as EAP actuators have advanced notably recently, they do not presently meet the actuation
specifications of most practical robotics. This paper considers the capabilities of EAP actuators relative to robotics’
requirements, and then portrays the authors’ novel techniques for lowering robotics’ actuation requirements for facial
expression robotics to within the capability range of contemporary EAP actuators.
The key is advances in the Structured-Porosity Elastomer Material (SPEM) manufacturing process first described
in [Hanson and White, 2004]. The SPEM process enables fine-grade control over the cellular structure of pores in an
elastomer, which results in a highly structured elastomeric spongelike material. This material requires substantially less
force to deform into expressive shapes. Of additional benefit for robotics, SPEM manufacturing also allows controlled
embedding of sensors, actuators, and other electronic or mechanical parts.

Smart Structures and Materials 2006: Electroactive Polymer Actuators and Devices (EAPAD), edited by Yoseph Bar-Cohen,
Proceedings of SPIE Vol. 6168, 616806, (2006) · 0277-786X/06/$15 · doi: 10.1117/12.659000

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 2.0 HUMANOIDS
Humanoids are expected to become common house-hold item by year 2050 (BBC News: “Rising of Humanoids”).
They will exhibit emotion, make decisions, and perform intelligent operations. They will incrementally acquire new
knowledge from environmental interactions and conduct tasks in an natural humanly ways. Already, humanoid robots
can autonomously perform task decomposition necessary to carry out high-level, complex commands given through
gesture and speech as shown in Fig. 1. Humanoids may prove to be the ideal robot design to interact with people and
will change the way we interact with machines and will impact how we interact with and understand each other.

Figure 1: extant Humanoids demonstrating striking similarity to human apperance and expressions. (a) pirates (USA),
(
(b) Repliee Q1 (Japan), and (c) Albert Hubo (USA/Korea).

3.0 PRESENT EAP CAPABILITIES AND TRENDS

EAP actuators have progressed rapidly in the last decade. EAP actuators close to readiness for actuating robots
include dielectric-elastomers at SRI International, and exchange polymer/metal composite (IMPC) actuators JPL,
EAMEX, Japan, University of New Mexico, and Washington University. In particular, the dielectric EAP actuators
developed at SRI International [Pelrine et al., 2004] have shown strain, response speed, and stored mechanical energy
density in the range of biological muscles [Full and Meijer, 1999]. SRI has produced a series of walking and running
bio-inspired robots actuated by dielectric elastomer EAPs [Pelrine et al 2004], which demonstrate feasibility of their use.
Other EAP actuators technologies may pull ahead to satisfy the needs of bio-inspired robots, and the specific
requirements of actuation are given in this paper as a goal for such work.

4.0 REQUIREMENTS OF VARIOUS TYPES OF ROBOTIC MOTION

The physical motion requirements of bio-robots differ greatly depending on the type of motion involved.
Legged-locomotion, winged flight, manipulation, and facial expression, each present unique actuation challenges that
vary further depending on scale, end application, and other factors [Brown, et al, 1997; Full et al, 1999]. Although a
deep analysis of robotic actuation requirements is beyond the scope of this paper, it is hoped that an elementary
evaluation will assist in deciding what types of robotic motion are reasonable short-term candidates for EAP actuation.
Sociable robotics emulate human facial expressions to provide a more intuitive interface between humans and
robots [Breazeal, 2001]. The actuation specifications required to emulate facial expressions are less restricted than those
of locomotion or manipulation. Instead of propelling or lifting, the only limits are determined by the material used to
emulate facial tissues: the softer and more pliable the material, the less force is required. In the past, sociable robotics
has turned to the practices of entertainment robotics (or “animatronics”) for its expressive skin materials [Hanson et al,
2003; Landon, 2003]. Animatronic figures are biomimetic, electro-mechanical puppets that populate numerous
themeparks and feature films. Animatronics tend to be expensive to design and build (restricting research and
creativity), limited in expressivity (the faces don’t make a full range of humanlike expressions), and power hungry
(limiting mobility and fusion with expressive humanoid bodies like the Asimo or Qrio). Altogether, the limitations of
animatronics technology prevent expansive use in social robotics, and generally limit usefulness outside niche
applications of films and theme parks.
Animatronics’ problems of costliness, low expressivity, and power consumption all result Even using solid
elastomers, emulated facial expressions are likely low enough in their actuation requirements to be viable candidates for

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 existing EAP actuation. If the robotic facial material can be are improved so as to require less force, this will bring EAP
actuation of synthetic facial expression well within the range of plausibility. Starting with a look at biology for
inspiration, this section discusses the differences of human skin versus solid elastomers (elastomers require much more
force), and proposes a compromise: high-elongation spongelike elastomers.
Elastomers also known as rubbers have an elastic deformation > 200%, consists of coil-like molecules that can
reversibly stretch by applying a force. Certain elatomers that do not easily crystalize during processing and have low
glass temperature can be easily deformed elastically when a force is applied. Most of the elastomers exhibit nolinear
elastic behavior and exhibit a slight discontinuity in the stress-strain curve. Figure 3 shows an schematic of the stress –
strain behavior for the typical elastomer. This discontinuity corresponds to the uncoiling of the chains after which
further deformation occurs by the stretching of the bonds. The stress required to produce deformation by bond stretching
increases significantly and thus restricts the direct usage of the elastomers as the skin material. Naturally, a strutural
modification is essential to reduce the stress requirements.
To resolve these issues, author David Hanson and Victor White demonstrated a series of methods for making
sponge-like elastomer materials that move more like facial soft-tissues [Hanson and White, 2004].
In particular, these techniques allow the structuring of pore-walls in elastomer foams, so that the elastomer foam
elongates much further that conventional foams, with much lower forces than equivalent solid elastomers. The resulting
materials, called “Frubber” (a contraction of flesh and rubber), wrinkle, crease, and amass, much more like skin than do
animatronics materials (see figure 2). They also consume very little power—less than 10W when affecting a full range
of facial expressions and speech-related mouth motions. In early tests, the material required less than 1/22nd the force
and energy to move into facial expressions relative to animatronics materials [Hanson and White, 2004].

Figure 2. Frubber robot expressions, consuming less than 10 watts.

Unfortunately, the forces required are not yet low enough for EAP actuation. Yet, the reduced energy
consumption promised use with battery-powered biped walking. Such bipedal walking promises to impact the
performance capability of robots in our world at large, expanding the range of possible social engagement and
interaction between robots and people.
Since spring 2002, the author has realized ten iteratively more expressive robot faces using Frubber materials.
Additionally, the social AI software must be refined to facilitate improved social engagement. We expect that a less
expensive, yet more design-flexible, hardware platform will generally enable more widespread software development
for this kind of robot. To make the robots more engaging and seemingly intelligent, author Hanson’s team has
implemented AI-driven intelligent interactive software using face tracking, face recognition, automatic speech
recognition, natural language processing, and speech synthesis. Much of this software is available open-source at the
author’s website, www.hansonrobotics.com. One example is the android portrait of sci-fi writer Philip K Dick (PKD-A)
(see figure 3), the PKD-A software (programmed by Andrew Olney of the University of Memphis) also incorporates
thousands of pages of the author’s writing into a conversational sketch of the deceased sci-fi writer’s mind. Such
literary and narrative aesthetic can be the key to designing humanlike robots that are socially engaging—a good
personality goes a long way. This technology combination in PKD won the AAAI 2005 first place award for Open
Interaction.
The author’s latest robot, a fully expressive portrait of Albert Einstein, further demonstrates the significance of
Frubber, mounting atop another Hubo that is customized to the character “Albert-Hubo” (see figure 4). Unveiled at the
APEC summit Nov. 2005 in Busan, Korea, the Albert Hubo greeted world leaders, schoolchildren, the public at large,
and the press media over the span of 5 days of presentations. The head of the robot, designed and built by the author’s
company Hanson Robotics Inc to be as realistic as possible, demonstrates realism in static expressions, dynamic action,

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 and (to some extent) interaction. Resoundingly, he was the hit of the show at the APEC summit [U.S. News, CNN, and
MSNBC, Nov. 2005].

I
Figure 3. Philip K Dick Android talking with people. Figure 4. Albert Hubo.

4.1 Facial Expressions: Techniques Required for Social Robots

Actuation of artificial human face muscle requires information on the displacement and force characteristics of each
muscle. Hanson has shown that there are 39 node points required to duplicate actual human face muscle on a robot head.
This muscle includes zygo smile, frown, forehead etc. as illustrated in the face chart matrix of artificial muscle shown in
Fig. 2. Broadly speaking, facial expression can be categorized into three groups: happy, unhappy and a combination of
both happy and unhappy expressions. Expressions like joy, love, laughter and high spirit are categorized as happy.
These are characterized by rising or relaxing the cheek muscle with escalating shape on the eyes whereas grief, anger,
fear, guilt etc are classified as unhappy. These group share similar action due to the involvement of downward arc of
frown and contraction of forehead. Other action such as surprise which open, relax mouth and open eyes widely is a
blend of both happy and unhappy.
In order to design the actuation technologies for the facial expression it is of paramount importance to
characterize each of these 39 node points in terms of force and displacement requirements. The lower are these
requirements the easier it will be to implement the conformal actuators based on EAP’s. In addition to conformity, there
are several other characteritics essential to replicate the expressions including, response to the dynamic stresses,
temperature and pressure, and linearity. So far the materials used to construct the faces have demanded high force for
providing the desired displacement which implies that the power required to drive these actuators is outside the practical
range.

4.2 Experimental Quantification Of Requirements For Facial Expression

Figure 5 shows the optical micrographs of the fabricated samples and its implementation in the actual face. These
micrographs illustrate the complex networking of the pores, micro-fluidic chambers, and bubbles. One interesting
observation that can be made from these micrgraphs is that pores and bubbles are interconnected at the length scales of
20 µm. It is expected that this arrangements plays a significant role is enhacing the deformation characteristics of the
elastomer. This figure also shows that there are some trapped impurities in the elastomer. The material requires less than
1/30th the force to compress relative to nonporous casts of the same silicone material as shown in Fig. 5. In facial
expression robotics, this is particularly advantageous as all expressions both compress facial soft tissues and elongate
facial soft tissues.

5.0 EXPERIMENTS
Strain gages are widely used for measurement such as force, pressure, torque, and strain. This is done by converting
these forms of input into mechanical strain using an elastic member, which is then converted into resistance change.

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 Finally the resistance change is converted into voltage using a bridge circuit. A combination of strain gauges and an
elastic body are also available commercially and come in different sizes and shapes. Before these instruments can be
used for measurement, however, they must be properly calibrated first.

A measurement instrument must be calibrated by applying inputs of known values (standards) and measuring its
output. Calibration involves comparison of the instrument with a higher standard and, thus, reduces bias errors. Once
this relationship is established or verified, the input values can be inferred from the measured values (often voltage)
accurately.

For this experiment, we used calibrated robotic manipulator to measure force versus displacement characteristics
of artificial human muscle faces. This is done by mounting the Hanson Fruber material which is used as a muscle on a
“Staurali” robotic manipulator. A displacement that brings about effective expression of each anchor is determined by
pulling the skin tightly. Each anchor points are attached to the manipulator tip and a required displacement
corresponding to that particular anchor is set to move. A command is provided to the manipulator tip in V programming
language. The load sensor on the manipulator arm records the force applied in displacing the anchor for an incremental
displacement of 0.05mm. Fig 6 demonstrates the experimental setup of the measurement system.

5.1 Experimental Results

The force verses displacement characteristics of most of the muscle are linear and maximum force and the
corresponding displacement is recorded and tabulated. The detail of each muscle characteristics is given in table 1. It is
observed that the experimental data is associated with some noise whose magnitude couldn’t affect the relevance of the
data.

Table 1 Maximum force and displacement of artificial face muscle

Facial Action Action Displacement, [mm] Force (N/lb)
0 Zygo Minor L&R 15 ,28 2 (0.44 )
1 Lower Lip Center 17.5 25 2 ( 0.44)
2 Brow Center 10, 20 2 (0.44)
3 Lids Upper 17.5 3 (0.67)
4,37 Frown L&R 15, 33 6 (1.34)
5,33 Smile Risorius L&R 22, 40 3 (0.67)
6,34 "oo" L&R 18, 40 2 (0.44)
7,39 Frown 3/4 L&R 15, 30 2.8 (0 .63)
8,32 Brow 3/4 L&R 15, 30 2 (0.44)
9,22 Smile Zygo L&R 22 , 40 3.5 (0 .79)
10 Squint Inner (L+R) 15, same 3 (0.67)
?11,18 Brow Outer L 13 24 2 (0.44)
12,38 Sneer L&R 15, same 2 ( 0.44)
13,35 Brow Furrow L&R 15, 30 2 ( 0.44)
14,21 Squint Outer L&R 15 ,same 2 ( 0.44)
15 Eye Turn L 17 ?
16 Eye Turn R 17.5 ?
17 Eyes Up/Down 10 ?
?18 Brow Outer R 13, 24 2.8 (0.63)
19 Lid Lower 15 1.5 ( 0.34)
23 Upper Lip Center 15, 22 2 (0.44)
24 Tilt
25 Upper Nod
26 Lower Nod
27 Turn
36 Jaw 53 6 (1.34)

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 Fig 7 illustrate F vs D graph for six line of action. The relative distance required for each action as well as the
force behaviors and their associated trend line can be inferred.

Impurity

Large size pore

Interconnection of
pores and bubbles

I.
1
r•• ' -
Joining of several pores

Figure 5. A cross-section of silicone SPEM, illustrating the microstructural characteristics and composite geometry. (a)
Samples used for the microscopy, (a) scale bar is 100 µm, (b) scale bar is 20 µm,, and (c) scale bar is 10 µm.

Fig 6 Experimental setup

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 Force Vs Displacement characteristics

S - ct lB --
Linefi
4
'it
-N
3 S
')__
2 - t ie22
Lie32

U S ID IS 20 26
Displacement (mm)

Fig 7 F vs. D characteristic curve for some of the action line

6.0 CONCLUSIONS
Determination of characteristics of the skin material used for facial expression robotics is essential for selection of
actuator from the existing once or for the one to be innovated specific to this application. The general trends of the force
verse displacement characteristic of most of the muscle are linear. The required force along with the maximum
displacement of each muscle is determined experimentally.
In a nutshell, the force and displacement characteristics of Frubber material that we use as a skin material for
facial expression robotics do have a linear relationship with a regression coefficient of R2 = 0.92-0.97. It is noticed that a
displacement of 14-25 mm depending on muscle type can demonstrate the actual facial expression with a force
requirement in the range of 2-4N. It is estimated that the forces required for practical application of EAP actuators for
facial expressions is .25 N.
To date, the authors have demonstrated that the forces required to elongate Frubber are 1 to 2 orders of magnitude
lower than that of a solid elastomer of the same chemical composition. It is expected that by structuring the pore walls
of the F’rubber material to have folding geometries, the authors may bring the force requirements down by 1-2 more
orders of magnitude. This concept is described further in future work, below.

6.1 Integrating EAPs and Bio-Inspired Robotics

Robotic faces are a superb platform for the convergence of state of the art EAPs and state of the art robotics. Here we
discuss how to integrate EAPs and SPEM emulated facial-expression robotics.
As described in chapter 18 of Electrically Actuated Polymer Actuators as Artificial Muscles, SPIE PRESS
[Hanson, 2004], requirements for EAP Usefulness to Entertainment would include: low voltage (30-V max), high strain,
high power density, robustness and durability, and the support of fully developed adjunct technology (fasteners, drivers,
etc.). Additionally, the following specifications would need to be met for EAP actuators to be reasonable for bio-

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 robotics: longevity should be in the hundreds of thousands of cycles or higher. Response time should be in the low
milliseconds. The speed of actuation needs to be at least 5-cm/sec (~2-in/sec). Strain should be at least 10% of the
length of the actuator. They should be inexpensive [less than $300 (US) for a midsize 2.5–10-cm (~1–4-inch) actuator
with driver]. For facial animation, the most useful actuators would be 2.5–7.5-cm actuators with 20% strain or
displacement, weighing a maximum 15 grams. For widespread applicability, EAP actuators and bio-inspired robotic
materials need to be manufacturable inexpensively and in bulk quanities.
The highest priorities among these goals, will be the objectives of 24mm displacement (strain), with .25N output
force, and .3s time to full displacement. To this end, we will need to further lower the force requirements of the F’rubber
from 8 N to .25 N for a 24mm displacement.
For toy applications, of course, the faces can be smaller and the skins thinner. Because of cube/square scaling
effects, the forces required will drop exponentially for smaller faces. So, with less displacement—10mm, the forces
required to actuate a doll-size face will be less than .25 N.
For human sized faces, however, new F’rubber pore-wall geometries are required.

6.2 Future Work

Unfolding a folded thin sheet of elastomer requires considerably less force than stretching an unfolded sheet of
the same elastomer material. With this principle in mind, the authors have begun CAD drawings of several exotic
folding geometries. Some of these geometries are curled into spirals, others spring-shaped, while still others are in the
form of accordion-like folds. These geometries are rendered as tiles that interlock into repeating, tesselated structures.
When these geometries are printed via selective laser sintering (SLS) in pure nylon, they are expected to exhibit
very low-energy unfurling. Alternatively, the structures will be rendered in a removable material, in the manner of
poragen leaching, so as to leave the structures imprinted into an elastomer of choice, such as silicone or urethane.

6.3 Conclusory Remarks

Many challenges remain to actuate robotics with EAP practically. The SPEM techniques require integration into
facial expression robotics, more thorough evaluations, formalization, and standardization of the SPEM materials are
required, and efforts need to be taken to integrate the SPEM materials with actual EAP actuators.
By bringing the threshold for facial expression robotics within today’s EAP actuation capabilities, it is hoped that
practical EAP application in facial expression robotics may be brought to near-term realization.

ACKNOWLEDGEMENTS
The author would like to thank Dr. Yoseph Bar-Cohen, this conference’s chair, for his guidance, patience and
helpful suggestions. Additional thanks go to Elaine Hanson, Kristen Nelson, and Paul McCarthy.

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