The need for low-cost robust meso-scale “smart” robots (manipulators) that have no discrete parts (monolithic), no sensors (“self-sensing”) and can be used in space-constrained systems, e.g., in microfactories, biomedical applications, etc., was the motivation for the current research. This study describes the design, fabrication and analysis of such a smart robot – a monolithic Micro/Meso Scale Manipulator (mMM), fabricated from Shape Memory Alloy powders (NiTi) by means of the laser-based Direct Metal Deposition (DMD) process.A first prototype, a functional part of the mMM – a SMA accordion spring type actuator was manufactured by DMD. The actuator provides a linear movement for the mMM due to the Shape Memory Effect (SME) property of SMAs. A new mathematical model describing the phase transformation kinetics in SMAs and a new analytical phase transformation function was developed. In the current work a “self-sensing” concept was explored and evaluated in an SMA wire actuator and applied to the SMA spring based actuator. A new mathematical model of the motion of the SMA wire- and spring- based actuators was developed.

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