Finite Element Analysis of Fiber-Reinforced Pneumatic Soft Actuators: A Hybrid Analytical–Numerical Framework

Pneumatic soft actuators have been drawing considerable attention in the field of soft robotics, thanks to their inherent flexibility, high power density, and safe interaction. However, the strong, intricate coupling between the material’s hyperelastic behavior and the reinforcement of anisotropic fibers creates significant challenges for both analytical modeling and numerical characterization of these actuators. In this paper, we design and fabricate a fiber-reinforced pneumatic soft actuator using Ecoflex 00-30 silicone rubber as the base material and helically wound fibers as the reinforcing layer. We set up a theoretical framework that combines the Neo-Hookean model for isotropic silicone rubber with a strain energy-based formulation for anisotropic wound fibers. This framework describes how the actuator is stretched, expanded, twisted, and bent. Finite element simulations are then carried out, focusing on three key design parameters: winding fiber density (three levels: high, medium, low), air cavity offset distance from the central axis (1, 2, 3, and 4 mm), and air cavity cross-sectional geometry (cube vs. cylindrical). The simulations reveal that a higher winding fiber density promotes more uniform stress distribution across both the strain and confinement layers. In contrast, a low fiber density can lead to local bulging and large stress variations, which ultimately compromises the bending performance. The offset distance of the air cavity from the neutral axis is directly linked to the bending curvature: a larger offset produces greater air cavity deformation and higher actuation efficiency. Furthermore, the cuboid air cavity yields a larger bending angle (experimentally validated up to 90° at 0.045 MPa) and better efficiency, while the cylindrical air cavity distributes stress more evenly across the outer surface of the strain layer and reduces stress concentration at the edges. These findings provide useful quantitative guidance for optimizing the structure of fiber-reinforced soft actuators and establish a framework for hybrid analytical–numerical prediction of their mechanical behavior.