Intuitively, prostheses with user-controllable stiffness could mimic the intrinsic behavior of the human musculoskeletal system, promoting safe and natural interactions and task adaptability in real-world scenarios. However, prosthetic design often disregards compliance because of the additional complexity, weight, and needed control channels. This paper focuses on designing a Variable Stiffness Actuator (VSA) with weight, size, and performance compatible with prosthetic applications, addressing its implementation for the elbow joint. While a direct biomimetic approach suggests adopting an Agonist-Antagonist (AA) layout to replicate the biceps and triceps brachii with elastic actuation, this solution is not optimal to accommodate the varied morphologies of residual limbs. Instead, we employed the AA layout to craft an elbow prosthesis fully contained in the user's forearm, catering to individuals with distal transhumeral amputations. Additionally, we introduce a variant of this design where the two motors are split in the upper arm and forearm to distribute mass and volume more evenly along the bionic limb, enhancing comfort for patients with more proximal amputation levels. We characterize and validate our approach, demonstrating that both architectures meet the target requirements for an elbow prosthesis. The system attains the desired 120° range of motion, achieves the target stiffness range of [2, 60] Nm/rad, and can actively lift up to 3 kg. Our novel design reduces weight by up to 50% compared to existing VSAs for elbow prostheses while achieving performance comparable to the state of the art. Case studies suggest that passive and variable compliance could enable robust and safe interactions and task adaptability in the real world.

This article has been accepted for publication in IEEE Transactions on Robotics. This is the author's version which has not been fully edited and content may change prior to final publication. Citation information: DOI 10.1109/TRO.2024.3492372