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The cylindrical cross-axis flexural pivot (CCAFP) is proposed as an ultra-compact flexure capable of being integrated into hollow cylindrical shafts, enabling shaft motion without inhibiting cables or other components inside the shaft. Mechanism geometry, materials, and manufacturing are proposed and the results analyzed and tested. A parametric finite element model of the CCAFP was created to analyze the force-deflection and strain-deflection relationships and the predicted behavior was verified by experiment. Analytic models of stress-limiting cam-surfaces suggest even larger motions may be possible when not limited by current practical constraints. The CCAFP is demonstrated and tested at multiple size scales and in multiple materials, ranging from 28.6 mm diameter 4130 steel (achieving 9 degrees of angular deflection) to 3 mm diameter NiTi (achieving an angular deflection of 85 degrees). The results are generalized to apply to a range of applications, and the CCAFP particularly shows promise for implementation in minimally invasive surgical instruments to decrease instrument size while maintaining instrument performance.

This work exploits the advantages of compliant mechanisms (devices that achieve their motion through the deflection of flexible members) to enable the creation of small instruments for minimally invasive surgery (MIS). Using flexures to achieve motion presents challenges, three of which are considered in this work. First, compliant mechanisms generally perform inadequately in compression. Second, for a ±90deg range of motion desired for each jaw, the bending stresses in the flexures are prohibitive considering materials used in current instruments. Third, for cables attached at fixed points on the mechanism, the mechanical advantage will vary considerably during actuation. Research results are presented that address these challenges using compliant mechanism principles as demonstrated in a two-degree-of-freedom (2DoF) L-Arm gripper.