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DESIGN AND PROTOTYPING OF A MODULAR AND SCALABLE COMPLIANT VARIABLE STIFFNESS MECHANISM OPERABLE IN THE THREE CARTESIAN DIRECTIONS - Masters Thesis

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Ben Zwiener

Project Timeline

Aug 2025 - Dec-2025

OVERVIEW

What are Variable Stiffness Mechanisms? VSMs (or VSAs) are mechanical or mechatronic devices capable of adjusting their stiffness by leveraging mechanical principles to modulate how a robotic system reacts to loads. Integrating these can include benefits like reduced wear and increased safety and performance. But they often suffer disadvantages like cumbersome sizes, intricate designs, and designed only for rotational degrees of freedom. Motivation & Objective As industrial robots expand, their energy use and wear become increasingly more important. Thus we introduce a novel Cartesian Variable Stiffness Mechanism (CVSM) mounted between the end effector and robot arm to reduce jerk and offer greater payload manipulability. Project Goals 1. Build a functional prototype operable in each of the Cartesian directions (X,Y,Z) 2. Independently tune stiffness in each direction 3. Be able to mount to any robot 4. Design to handle 5 lbs and permit +/- 10mm deflection

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SKILLS

Manual Lathe and MillCNC MillFusion 360 CAM3D PrintingSolidWorksUniversal Robot ProgrammingMATLABMechatronics
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Ben Zwiener

Mechanical Engineer and Robotics Specialist

I am a mechanical engineering graduate student at the University of Nebraska-Lincoln specializing in robotics and compliant mechanisms. My research focuses on variable stiffness mechanisms for industrial robotics, with publications at ASME IDETC conferences and a pending U.S. patent. I have hands-on experience in CAD design, FEA simulation, mechatronic prototyping, and manufacturing. My internship at Relativity Space involved designing modular gearboxes and performing structural analysis. I combine theoretical knowledge with practical skills in fabrication, testing, and programming to develop innovative engineering solutions.